Electrocoagulation unit

ABSTRACT

An electrocoagulation unit that may include an outer shell, and a set of electrodes disposed within the inner housing. Each electrode is separated from an adjacent electrode by an electrode gap spacing. The outer shell may further include a fluid inlet; a fluid outlet; a first busbar opening with a first busbar gland associated therewith.

BACKGROUND Field of the Disclosure

This disclosure generally relates to processes and systems, and relatedunits, for improved treatment of a fluid. Particular embodiments hereinrelate to removing impurities and other contaminants, for exampleorganics, from liquids such as water, using an electrochemical process.Other embodiments herein relate to the use of electrocoagulation (EC)for the treatment of water in an offshore environment, such as on or inassociation with a Floating Production Storage and Offloading (FPSO)vessel.

Background of the Disclosure

In many respects, clean water may be thought of as the most in-demandcommodity around the world. The need for clean water is prevalent intoday's residential, municipal, and industrial settings. One area ofrelevance is the oil and gas (O&G) industry, where consumption of cleanwater, and production of contaminated water, continue to dramaticallyrise. To be sure, the background of the disclosure and embodimentsherein are relevant elsewhere, such as agricultural, medical, orwastewater treatment, be it onshore or offshore, as well as otherfluids, but for brevity may focus on water and O&G.

Generally speaking, produced water may be a single- or multi-phasecomposition produced from an underground formation to the surface duringoil and gas production. Produced water may include solids, dispersedoil, dissolved organic compounds, production chemicals, heavy metals,and even radioactive minerals. Some of these elements occur naturally inproduced water while others may be chemicals previously used forwell-stimulation, completion, production, etc.

Produced water may come from other sources as well. For example, sloptanks, flowbacks, and frac water all represent produced water streamsthat do not actually originate from underground formations.

While produced water presents its own challenges in an onshore setting,it is nothing short of problematic for offshore. Not only must theproduced water be treated to a level sufficient to allow it to bedischarged into the ocean, reinjected into a disposal well, or shippedto shore via limited pipeline capacity, but deck space and weight limitsfor offshore vessels is extremely limiting.

Offshore treatment routinely defers to chemical treatment, followed bymechanical treatment, followed by filtration. Typical offshore treatmentskids require a significant footprint for associated equipment—justgetting the equipment onto a vessel as a first step is acost-prohibitive logistical quagmire. Filtration skids alone demandextensive amount of filtration media that rapidly foul and requireconstant operator attention. Conventional systems like this employfilter cartridges or bulk media to adsorb organics and remove or reducesolids. On an offshore operation, the space necessary to store thecartridges both new and expended is a source of operational, safety,economic and liability concerns (the same also apply to onshore).

Electrocoagulation (EC) is a different type of treatment process used bya variety of industries (particularly water related) to destabilizecontaminants and hold them in solution using an electrical charge. ECuses an oxidation-reduction (redox) reaction as is known to one of skillin the art. FIG. 1 illustrates a conventional EC process 100 thattraditionally utilizes an EC unit 111 configured with an anode 112 and acathode 113 separated by a distance or gap (exaggerated here) 115,stimulated by a power source 114.

A fluid (or inlet fluid) F_(i) for treatment is fed to the unit 111 byway of an inlet 116. Suspended, stabilized and emulsified contaminantsexist in fluid. Water in particular is suitable for EC, as it is polarand holds contaminants, such as heavy metals and colloids, in solutionwith electrical charges. When power is applied, suspended and stabilizedcontaminants are destabilized, and break into smaller particles, andemulsified fluids are de-emulsified. The power connection is typically‘dry’ (i.e., the connection point between the electrode and the powerline is not within a liquid such as water).

Electrons 121 produced during EC affect the polarity of the fluidallowing contaminant materials to precipitate. Resultant metal ions 120form in-situ chemical coagulant that destabilize, change or neutralizecontaminant charges, resulting in formation of ‘floc’ or ‘flocculent’118 (sometimes also ‘concentrated sludge’ 118 a). The floc 118 may floatto the surface (or sink) as a result of differences in density. Thetreated fluid and generated floc F_(o) will exit the unit via outlet 117for further processing to remove the generated floc.

However, conventional EC is underpinned with a myriad of problems.First, during the EC process, electrodes are sacrificed in order toproduce coagulating ions, and become coated and fouled (sometimesrapidly) with a non-conducting oxide—this is particularly the case whenprocessing wastewater with high concentrations of dissolved solids andscaling potential. Known as ‘passivation’, this results in the ECprocess having reduced efficiency, increased power consumption, spatialconsiderations, time-consuming maintenance, cleaning (with hazardouschemicals), higher costs for replacing of electrodes. Fluid treatmentrates slow, power consumption increases, and effluent quality degradesas electrodes scale and pit. The required handling and cleaning ofpassivated anodes and cathodes provides additional risk to operators.

Another problem with EC is that it typically is used in mid-rangeconductivity systems (as higher conductivity means faster passivation).Such systems require the electrodes to be closely spaced, such as 0.25″to 2″ (for suitable current transfer), which means that upper limit flowrates are significantly limited. Conventional EC also consumes a largefootprint, with heavy equipment. More power is also required in order tohave adequate current transfer. Example conductivities include 5.5×10⁻⁶S/m (or less) for ultrapure water, 0.005-0.05 S/m for drinking water,and about 5 S/m for seawater.

Additional problems associated with EC pertain to the production ofgases, such as O2 or H2, which need to be adequately contained andaccounted for.

And yet even further problematic are the post-EC treatment processes. Tosufficiently separate the floc (‘floc and drop’ or gravity separation)from treated water requires extensive time and space. The largest amountof equipment required in the entire process are typically tanks andseparation equipment needed for this indispensable last step.

Any one of these detriments (let alone combinations) has leftconventional EC not previously contemplated for successful use onoffshore vessels or for high flow rate operations.

It therefore follows that there is a need for simple, energy-efficientand cost-effective process, system, and related units, for treatingfluids, such as produced water, to produce a high-purity product. Thereis a need for a treated product that is suitable for environmentallysafe disposal, reuse in an oil and gas production facility, as well asother uses such as industrial, medical, or agricultural.

There is a need for an improved offshore EC processes that have any oflow operating costs, reduced capital costs, safe to use, compactfootprint, and substantial or complete elimination of undesiredpassivation.

There is a need for an EC process readily usable with high-capacity flowrates. There is a need in the art for a liquid treatment process thatdoes not require filtration media or chemical treatment and minimizeswaste and its associated disposal and long-term liability challenges.There is a need in the art for equipment units that may be retrofittedor coupled with to any existing liquid treatment facility.

SUMMARY

Embodiments herein pertain to an electrocoagulation unit that mayinclude one or more of: an outer shell, an inner housing which may becoupled with the outer shell; a set of electrodes disposed within theinner housing, each electrode being separated from an adjacent electrodeby an electrode gap spacing. The outer shell may further include a fluidinlet; a fluid outlet; a first busbar opening; a and second busbaropening.

The unit may include a first pressure gland assembly sealingly coupledwith the first busbar opening. The pressure gland may include a firstgland power bar disposed within a first gland body. The unit may includea second pressure gland assembly sealingly coupled with the secondbusbar opening. The second pressure gland assembly may further include asecond gland power bar disposed within a second gland body.

The unit may include a first busbar coupled with the first gland powerbar. The first busbar may be coupled with every other electrode of theset of electrodes. The unit may include second busbar coupled with thesecond gland power bar. The second busbar may be coupled in analternating manner with every electrode of the set of electrodes notcoupled with the first busbar.

The unit may have a plurality (such as individual pieces) of sacrificialmedia disposed between each respective adjacent pair of electrodes.

An at least one electrode of the set of electrodes may have a(cumulative—front and back, etc.) surface area in a range of 1000 inchesto 2000 inches. An at least one electrode of the set of electrodes mayhave an electrode thickness in a thickness range of 0.1 inches to 2.5inches. The unit may have an electrode gap spacing between an at leasttwo of the set of electrodes comprises a gap distance of 4 inches to 8inches.

Any pieces of the sacrificial media may have perforations. In aspects,there may be set of perforations in a range of 3 perforations to 9perforations. Any of the pieces may have a media thickness of thesacrificial media is in a range of 0.001 inches to 0.005 inches.Naturally these dimensions refer to the media prior to use.

Any of the bars may have a main bar body made of conductive metal. Anyof the bars may have a surface coating. In embodiments, any of the barsmay have a first surface portion coated with a dielectric material, anda second surface portion coated with a conductive material.

Any of the electrodes of the set of electrodes may have a main electrodebody made of platinum. Any of the electrodes may have an outer electrodesurface coating. The surface coating may be a noble metal. Similarly,any jumpers of the unit may be made of a conducting material. Any of thejumpers may have a first jumper surface portion coated with thedielectric material, and a second jumper surface portion coated with theconductive material.

Embodiments herein pertain to an electrocoagulation unit that mayinclude one or more of: an outer shell (which may further have: a firstbusbar opening); an inner housing within the outer shell; a set ofelectrodes disposed within the inner housing, each electrode beingseparated from an adjacent electrode by an electrode gap spacing; afirst pressure gland assembly sealingly coupled with the first busbaropening, the first pressure gland assembly further comprising a firstgland power bar disposed within a first gland body; a first busbarcoupled with the first gland power bar, and further coupled with everyother electrode of the set of electrodes; and a plurality (such asindividual pieces) of sacrificial media disposed between each respectiveadjacent pair of electrodes.

Still other embodiments herein pertain to an electrocoagulation systemthat may include an electrocoagulation unit operably associated with apowers source and a flotation vessel.

The electrocoagulation unit may include an outer shell, the outer shellfurther may have: a first busbar opening; an inner housing within theouter shell. There may be a set of electrodes disposed within the innerhousing. Each of the electrodes may be separated from an adjacentelectrode by an electrode gap spacing. There may be first pressure glandassembly sealingly coupled with the first busbar opening. The firstpressure gland assembly may include a first gland power bar disposedwithin a first gland body. There may be a first busbar coupled with afirst end of the first gland power bar, and further coupled with everyother electrode of the set of electrodes. There may be a plurality ofsacrificial media disposed between each respective adjacent pair ofelectrodes.

The system may include the electrocoagulation unit pressurized to anoperating pressure in a range of about 50 psi to 160 psi. The unit maybe operated at a flow rate in a range of 200 gpm to 500 gpm. The flow offluid entering the electrocoagulation unit may have 1000 ppm to 5000 ppmtotal suspended solids (TSS).

The power source may be rectifier electrically coupled with a second endof the second gland power bar.

The power source may be operable to amps to the electrocoagulation unitin an amperage range of 300 amps to 500 amps. The power source may beoperable to provide volts to the electrocoagulation unit in a voltagerange of 1 volt to 20 volts.

The system may include the flotation unit operably associated with aninjection system. The injection system may be operated to form aninjection stream comprising bubbles having an average effective diameterin a range of 10 microns to 300 microns. The treated fluid may bereceived into the flotation vessel, and may mix with the injectionstream.

Any of the electrodes may have a main electrode body made of platinum,and any of the electrodes may have outer electrode surface coating madeof a metal material. The metal material may be or include a noble metal,such as ruthenium.

Any piece of the sacrificial media disposed into the electrocoagulationunit may include or be made of multivalent ion producing metal. Anypiece disposed therein may have a media thickness is in a range of 0.001inches to 0.005 inches.

Embodiments herein pertain to a method for removing contaminants from afluid that may include one or more steps of: disposing an amount of asacrificial media into an electrocoagulation unit; operating theelectrocoagulation unit at a pressure above atmospheric; receiving thefluid into the electrocoagulation unit; providing power to theelectrocoagulation unit from a power source to electrochemically treatthe fluid to form a treated fluid with a floc comprising coagulatedcontaminants; transferring the treated fluid to a flotation vessel;removing at least some of the floc via flotation to form a secondarytreated stream; removing other contaminants of the secondary treatedstream with a compressible media filtration vessel to form a treatedproduct.

Other embodiments herein pertain to method for removing contaminantsfrom a contaminated water stream that may include one or more steps of:disposing a plurality of individual pieces of sacrificial media into anelectrocoagulation unit; operating the electrocoagulation unit at apressure in a range of 50 psi to 160 psi; transferring the contaminatedwater stream into the electrocoagulation unit; providing power to theelectrocoagulation unit from a power source to electrochemically treatthe contaminated water stream to form a treated water stream with a flocportion comprising coagulated contaminants; and transferring the treatedwater stream out of the electrocoagulation unit.

The electrocoagulation unit of the method and respective components mayin accordance with embodiments herein. The flotation vessel of themethod and respective components may be in accordance with embodimentsherein.

Still other embodiments herein pertain to an electrocoagulation unitthat may include one or more of: an outer shell comprising a firstbusbar opening; an inner housing within the outer shell; a set of 4 to10 electrodes disposed within the inner housing, each electrode beingseparated from an adjacent electrode by an electrode gap spacing in arange of 5 inches to 7 inches; a first pressure gland assembly sealinglycoupled with the first busbar opening, the first pressure gland assemblyfurther comprising a first gland power bar disposed within a first glandbody; a first busbar coupled with the first gland power bar, and furthercoupled with every other electrode of the set of electrodes; and aplurality of sacrificial media disposed between each respective adjacentpair of electrodes.

In still yet other embodiments an electrocoagulation treatment systemmay include an electrocoagulation unit electrically coupled with a powersource.

These and other embodiments, features and advantages will be apparent inthe following detailed description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

A full understanding of embodiments disclosed herein is obtained fromthe detailed description of the disclosure presented herein below, andthe accompanying drawings, which are given by way of illustration onlyand are not intended to be limitative of the present embodiments, andwherein:

FIG. 1 shows an overview process diagram of a conventional EC process;

FIG. 2 shows an overview process diagram of a fluid treatment systemusing EC according to embodiments of the disclosure;

FIG. 3 shows an isometric view of customer interface system according toembodiments of the disclosure;

FIG. 4A shows an isometric view of an EC unit with an inner housingaccording to embodiments of the disclosure;

FIG. 4B shows a side view of an EC unit (shown with partial cut-away)coupled with a rectifier according to embodiments of the disclosure;

FIG. 4C shows a partial side cross-sectional view of an inner housingdisposed within an EC unit according to embodiments of the disclosure;

FIG. 4D shows a downward view of a perforated insert for the EC unit ofFIG. 4C according to embodiments of the disclosure;

FIG. 5A shows a side view of a wavy media according to embodiments ofthe disclosure;

FIG. 5B shows a side view of a loose spiral media according toembodiments of the disclosure;

FIG. 5C shows a side view of a tight spiral media according toembodiments of the disclosure;

FIG. 5D shows a side view of a curved media according to embodiments ofthe disclosure;

FIG. 5E shows a side view of a combination linear-curvilinear mediaaccording to embodiments of the disclosure;

FIG. 6A shows an isometric view of a pressure gland assembly accordingto embodiments of the disclosure;

FIG. 6B shows a partial side cross-sectional component breakout view ofa pressure gland assembly associated with an EC unit and a spool pieceaccording to embodiments of the disclosure;

FIG. 6C shows a partial side cross-sectional assembled view of thecomponents of FIG. 6B;

FIG. 7A shows a partial side cross-sectional view of a coated busbarcoupled with a coated electrode (with a coated jumper therebetween)according to embodiments of the disclosure;

FIG. 7B shows a close-up cross-sectional view of the coupled componentsof FIG. 7A according to embodiments of the disclosure;

FIG. 7C shows a component view of a flexible jumper according toembodiments of the disclosure;

FIG. 8A shows a partial internal side view of a dissolved gas floatation(DGF) vessel of a DGF skid according to embodiments of the disclosure;

FIG. 8B shows a partial internal side view of a compressed media vesselof a filtration skid according to embodiments of the disclosure;

FIG. 9A shows a horizontally oriented combination dissolved gasfloatation-compressible media filtration vessel according to embodimentsof the disclosure;

FIG. 9B shows a partial-cut side view of a vessel like that of FIG. 9Aaccording to embodiments of the disclosure;

FIG. 9C shows a partial-cut overhead view of a vessel like that of FIG.9A according to embodiments of the disclosure;

FIG. 9D shows a close-up view of a dispersion member suitable for avessel like that of FIG. 9A according to embodiments of the disclosure;

FIG. 9E shows a vertically oriented combination dissolved gasfloatation-compressible media filtration vessel according to embodimentsof the disclosure; and

FIG. 10 shows a partial cross-sectional side view of a combinationelectrocoagulation-flotation-filtration vessel according to embodimentsof the disclosure.

DETAILED DESCRIPTION

Herein disclosed are novel apparatuses, units, systems, and methods thatpertain to improved fluid treatment and aspects related thereto, detailsof which are described herein.

Embodiments of the present disclosure are described in detail withreference to the accompanying Figures. In the following discussion andin the claims, the terms “including” and “comprising” are used in anopen-ended fashion, such as to mean, for example, “including, but notlimited to . . . ”. While the disclosure may be described with referenceto relevant apparatuses, systems, and methods, it should be understoodthat the disclosure is not limited to the specific embodiments shown ordescribed. Rather, one skilled in the art will appreciate that a varietyof configurations may be implemented in accordance with embodimentsherein.

Although not necessary, like elements in the various figures may bedenoted by like reference numerals for consistency and ease ofunderstanding. Numerous specific details are set forth in order toprovide a more thorough understanding of the disclosure; however, itwill be apparent to one of ordinary skill in the art that theembodiments disclosed herein may be practiced without these specificdetails. In other instances, well-known features have not been describedin detail to avoid unnecessarily complicating the description.Directional terms, such as “above,” “below,” “upper,” “lower,” “front,”“back,” etc., are used for convenience and to refer to general directionand/or orientation, and are only intended for illustrative purposesonly, and not to limit the disclosure.

Connection(s), couplings, or other forms of contact between parts,components, and so forth may include conventional items, such aslubricant, additional sealing materials, such as a gasket betweenflanges, PTFE between threads, and the like. The make and manufacture ofany particular component, subcomponent, etc., may be as would beapparent to one of skill in the art, such as molding, forming, pressextrusion, machining, or additive manufacturing. Embodiments of thedisclosure provide for one or more components to be new, used, and/orretrofitted to existing machines and systems.

Various equipment may be in fluid communication directly or indirectlywith other equipment. Fluid communication may occur via one or moretransfer lines and respective connectors, couplings, valving, and soforth. Fluid movers, such as pumps, may be utilized as would be apparentto one of skill in the art.

Numerical ranges in this disclosure may be approximate, and thus mayinclude values outside of the range unless otherwise indicated.Numerical ranges include all values from and including the expressedlower and the upper values, in increments of smaller units. As anexample, if a compositional, physical or other property, such as, forexample, molecular weight, viscosity, melt index, etc., is from 100 to1,000. it is intended that all individual values, such as 100, 101, 102,etc., and sub ranges, such as 100 to 144, 155 to 170, 197 to 200, etc.,are expressly enumerated. It is intended that decimals or fractionsthereof be included. For ranges containing values which are less thanone or containing fractional numbers greater than one (e.g., 1.1, 1.5,etc.), smaller units may be considered to be 0.0001, 0.001, 0.01, 0.1,etc. as appropriate. These are only examples of what is specificallyintended, and all possible combinations of numerical values between thelowest value and the highest value enumerated, are to be considered tobe expressly stated in this disclosure. Numerical ranges are providedwithin this disclosure for, among other things, the relative amount ofreactants, surfactants, catalysts, etc. by itself or in a mixture ormass, and various temperature and other process parameters.

Terms

The term “connected” as used herein may refer to a connection between arespective component (or subcomponent) and another component (or anothersubcomponent), which can be fixed, movable, direct, indirect, andanalogous to engaged, coupled, disposed, etc., and can be by screw,nut/bolt, weld, and so forth. Any use of any form of the terms“connect”, “engage”, “couple”, “attach”, “mount”, etc. or any other termdescribing an interaction between elements is not meant to limit theinteraction to direct interaction between the elements and may alsoinclude indirect interaction between the elements described.

The term “fluid” as used herein may refer to a liquid, gas, slurry,multi-phase, etc. and is not limited to any particular type of fluidsuch as hydrocarbons.

The term “fluid connection”, “fluid communication,” “fluidlycommunicable,” and the like, as used herein may refer to two or morecomponents, systems, etc. being coupled whereby fluid from one may flowor otherwise be transferable to the other. The coupling may be direct orindirect. For example, valves, flow meters, pumps, mixing tanks, holdingtanks, tubulars, separation systems, and the like may be disposedbetween two or more components that are in fluid communication.

The term “pipe”, “conduit”, “line” or the like as used herein may referto any fluid transmission means, and may be tubular in nature.

The term “composition” or “composition of matter” as used herein mayrefer to one or more ingredients, components, constituents, etc. thatmake up a material (or material of construction). Composition may referto a flow stream of one or more chemical components.

The term “chemical” as used herein may analogously mean or beinterchangeable to material, chemical material, ingredient, component,chemical component, element, substance, compound, chemical compound,molecule(s), constituent, and so forth and vice versa. Any ‘chemical’discussed in the present disclosure need not refer to a 100% purechemical. For example, although ‘water’ may be thought of as H2O, one ofskill would appreciate various ions, salts, minerals, impurities, andother substances (including at the ppb level) may be present in ‘water’.A chemical may include all isomeric forms and vice versa (for example,“hexane”, includes all isomers of hexane individually or collectively).

The term “water” as used herein may refer to a pure, substantially pure,and impure water-based stream, and may include waste water, processwater, fresh water, seawater, produced water, slop water, treatedvariations thereof, mixes thereof, etc., and may further includeimpurities, dissolved solids, ions, salts, minerals, and so forth. Waterfor a frac fluid can also be referred to as ‘frac water’.

The term “frac fluid” as used herein may refer to a fluid injected intoa well as part of a frac operation. Frac fluid is often characterized asbeing largely water, but with other constituents such as proppant,friction reducers, and other additives or compounds.

The term “produced water” as used herein may refer to water recoveredfrom a subterranean formation or other area near the wellbore. Producedwater may include flowback water, brine, salt water, or formation water.Produced water may include water having dissolved and/or free organicmaterials. Produced water may refer to water from non-wellbore relatedprocesses, such as potable water treatment, sewage treatment, andequipment and building maintenance.

The term “electrochemical” as used herein may refer to generatingelectrical energy from a chemical reaction(s) or using electrical energyto cause a chemical reaction(s). An example electrochemical process mayinclude electrocoagulation.

The term “electrocoagulation” (or “EC”) as used herein may refer to anelectrochemical process that results in coagulation of a desiredcomponent(s) from a fluid, such coagulating an organic in the presenceof water.

The term “conductivity” or “electrical conductivity” as used herein mayrefer to a measure or quantification of a material's ability to conduct(or pass, transfer, transmit, etc.) an electric current. The higher thevalue, the greater the ability to conduct.

The term “salt” as used herein may refer to an ionic compound. A saltcan be electrically neutral (i.e., no net charge).

The term “polymeric”, “polymer-based”, and the like may refer to achemical (or material thereof) made of a polymer. “Polymeric-based” asused herein may refer to a chemical or chemical blend (or materialthereof) that includes or has a polymeric constituent as part of itscompositional makeup.

The term “treatment” (or treating, treated, treat, etc.) as used hereincan refer to an action such as purifying, separating, charging, heating,drying, cleaning, and so forth. One example may include ‘treating’ amulti-phase fluid to separate phases. Another example may include‘treating’ a substantially aqueous (water) stream to remove anon-aqueous component.

The term “impurity” as used herein may refer to an undesired component,contaminant, etc. of a composition. For example, a hydrocarbon ororganic component may be an impurity of a water stream.

The term “passivation” as used herein may refer to the scaling,oxidation, and pitting of an anode and/or a cathode during EC.Passivation is known to be driven by a fluid's scaling potential andTotal Dissolved Solids (TDS) concentration, and may occur rapidly uponinitiation of EC.

The term “skid” as used herein may refer to one or more pieces ofequipment operable together for a particular purpose. For example, an‘EC skid’ may refer to one or more pieces of equipment operable toprovide or facilitate an EC process. A skid may be mobile, portable, orfixed. Although ‘skid’ may refer to a modular arrangement of equipment,as used herein may be mentioned merely for a matter of brevity andsimple reference, with no limitation meant. Thus, skid may be comparableor analogous to zone, system, subsystem, and so forth.

The term “skid mounted” as used herein may refer to one or more piecesoperable together for a particular purpose that may be associated with aframe- or skid-type structure. Such a structure may be portable orfixed.

The term “engine” as used herein may refer to a machine with movingparts that converts power into motion, such as rotary motion. The enginemay be powered by a source, such as internal combustion.

The term “motor” as used herein may be analogous to engine. The motormay be powered by a source, such as electricity, pneumatic, orhydraulic.

The term “drive” (or drive shaft) as used herein may refer to amechanism that controls or imparts rotation of a motor(s) or engine(s).

The term “pump” as used herein may refer to a mechanical device suitableto use an action such as suction or pressure to raise or move liquids,compress gases, and so forth. ‘Pump’ can further refer to or include allnecessary subcomponents operable together, such as impeller (or vanes,etc.), housing, drive shaft, bearings, etc. Although not always thecase, ‘pump’ can further include reference to a driver, such as anengine and drive shaft. Types of pumps include gas powered, hydraulic,pneumatic, and electrical.

The term “frac operation” as used herein may refer to fractionation of adownhole well that has already been drilled. ‘Frac operation’ can alsobe referred to and interchangeable with the terms fractionation,hydrofracturing, hydrofracking, fracking, fracing, and frac. A fracoperation can be land or water based.

The term “offshore” as used herein may refer to an above-surface (but onwater), as well as subsea, environment. Vessels suitable for workingoffshore may include a Floating Production Storage and Offloading (FPSO)and a Floating Storage and Offloading (FSO), each known for beinginvolved in production, receiving, transporting, storage, and offloadingof hydrocarbonaceous materials. An offshore vessel may include aplatform or structure fixed or floating over water. Other examplesinclude Tension Leg Platform (TLP) SPAR, Shallow Water Complex, GravityBase System (GBS) or Compliant Towers.

The term “utility fluid” as used herein may refer to a fluid used inconnection with the operation of a heat generating device, such as alubricant or water. The utility fluid may be for heating, cooling,lubricating, or other type of utility. ‘Utility fluid’ can also bereferred to and interchangeable with ‘service fluid’ or comparable.

The term “mounted” as used herein may refer to a connection between arespective component (or subcomponent) and another component (or anothersubcomponent), which can be fixed, movable, direct, indirect, andanalogous to engaged, coupled, disposed, etc., and can be by screw,nut/bolt, weld, and so forth.

The term “porosity” as used here may refer to the ratio, sometimesexpressed as a percentage, of the void spaces, or interstices, offiltration media to the total volume of the filtration media.

The term “collector size” as used herein may refer the average effectivediameter or spacing pores of the filtration media. The collector sizeand the porosity values may be modified may adjusting size of anassociated compression chamber.

Any surface of (sub)components described herein may have a coating, asurface coating, etc. The coating may be applied or otherwise formed inany suitable manner over an inner body, such as by spraying, shrinking,heat, plating, sintering, and so forth. Coatings may vary. For example,any surface of a conductive component, such as a metallic or alloy bar,exposed to a liquid may be coated with a dielectric or other type ofnon-conducting material, such as Plastisol.

Just the same, any surface of the same or other conductive componentthat may be coupled with another component (e.g., a metal-to-metalconnection) may be coated with a conducting (includinghighly-conducting) material, such as platinum. In this respect somesurfaces may have a dual coating, such as one portion of a coating thatis non-conductive, and another portion of the coating this isconductive. Moreover, fastening devices may be coated and/ormulti-coated in the same manner.

While the thickness of any respective coating along a particularcomponent may vary, embodiments herein may include a generally uniformsurface coating thickness. The thickness may be about 5 mils to about 50mils (a mil being equal to 0.001″). In embodiments, the thickness may beabout 20 mils to about 40 mils.

Referring now to FIG. 2, an overview process diagram of a fluidtreatment system using EC, in accordance with embodiments disclosedherein, is shown. Fluid treatment system 200 may include one or morecomponents (or subcomponents) coupled with existing equipment. System200 may be skid mounted or may be a collection of skid units. System 200may be suitable for onshore and offshore environments.

System 200 may include a customer interface system (CIS) 201. The CIS201 may be configured to interface or couple with a unit, operation,system, etc. whereby an incoming fluid from a source operation 206 maybe fed to the CIS 201, such as via a connecting between source operationfeedline 203 to CIS inlet 202. The source operation 206 may generally beany operation from which a source fluid may be received by the system200 for treatment thereof. The source operation 206 may occur on or beassociated with an offshore vessel, such as an FPSO.

Although not shown here, the CIS 201 may have various valves, flanges,pipes, pumps, utilities, monitors, sensors, controllers, flow meters,safety devices, etc., for accommodating sufficient universal couplingbetween the system 200 and any applicable feedline/feed source of afluid to be treated from a source operation 206. The CIS 201 may be influid communication with a wellbore, wellhead, operating system,production system, tank etc. associated with the source operation 206.The source of fluid may also be a natural or free-standing source, suchas a pond (natural or manmade), a lagoon, lake, river, etc. The CIS 201may have a monitor operable to ensure the fluid stream is suitable forthe system 200. The CIS 201 may have a return or bypass line 204 for inthe event the fluid stream may be deemed unsuitable, and thus the fluidstream may be transferred elsewhere from the system 200.

Provided the fluid meets predetermined specification, the fluid may passto a pretreatment (PT) skid 205. The pretreatment skid 205 may includeone or more units for treating a single- or multi-phase fluid. Inembodiments, the pretreatment skid 205 may include a separator operableto treat a 2-, 3-, or 4-phase fluid. For example, the fluid may be awater-based stream with an organic phase, as well as solids (includingsuspended, dissolved, etc.) and gases, that may be treated to separationvia PT skid 205.

PT skid 205, which may include chemical injection, may be used to removelarge and/or easily separable components, such as bulk solids and freeoil. The separated components may be returned to source operation 206,recycled, disposed of, or otherwise transferred from the skid 205 (orsystem 200) as desired.

PT skid 205 may include one or more separators configured with a screenor other suitable device, an agitator (mixer), one or more injectionports, and so forth. When PT skid 205 includes a mixer, the mixer may beoperable to not only mix but also to separate out a side stream ofseparated contaminants.

In embodiments, the PT skid 205 may include a hydrocyclone or cyclonicseparator, which may be suitable to both mix and separate out adiscontinuous phase from a continuous phase liquid. For example, in sucha device, heavy components such as solids may be shunted to the outsideof the continuous flow stream for collection. Similarly, lightcomponents, such as an aliphatic organic stream, may readily coalesce inthe center of the continuous flow stream.

Other components suitable for the PT skid 205 may include, but need notbe limited to, coalescers (or coalescing systems such as beds), chemicalinjectors, medial filtrations devices, API oil separators, and the like,including by way of example a Voraxial-type separator provided by EnviroVoraxial Technology, Inc.

As the source operation 206 may vary, it may be desirous for system 200to include or accommodate capability for suitable pressure control.Thus, the PT skid 205 may include depressurization capability, which mayaid or facilitate separation. In addition, or in the alternative, thesystem 200 may include a depressurization (DP) skid 207.

Although depressurization may occur at any point within system 200, FIG.2 illustrates pretreated fluid may be transferred from the PT skid 205to the DP skid 207. The system 200 may include degasification anddepressurization prior to fluid being transferred to the EC skid 208.Just the same, the DP skid 207 may be bypassed or not used at all. Thismay be the case when an EC skid 208 operates under pressure, wheredepressurization may occur further downstream, such as in apost-treatment skid 209.

The DP skid 207 may include one or more units operable to control theflow rate and pressure of a fluid received therein. In embodiments thefluid may be transferred directly to skid 207 from the source operation206. In aspects, the DP skid 207 may include a depressurization vessel210 configured to vent to ambient conditions or to process flare. Thedepressurization vessel 210 may be configured with an inlet and outletwith either manual or automated control.

The depressurization vessel 210 may have a conical bottom, which may besuitable to divert solids that may freely settle to the bottom of thevessel 210. The DP skid 207 may have one or more depressurizationvessels 210 arranged in parallel, series, or as otherwise may bedesired. The depressurization vessels 210 need not be the same.

The pressure of fluid from the PT skid 205 and/or depressurization skid207 may be anywhere in the range of about 5 psi to about 225 psi. Fluidfrom any of source 206, skid 205, skid 207, etc. may be fed to EC skid208, which may include an operable (sub)system employing an EC processto promote electrolytic oxidation, emulsion destabilization, andflocculation. The EC skid 208 may utilize subject matter of U.S. Pat.No. 8,431,010, which is incorporated herein by reference in its entiretyfor all purposes, and particularly as it pertains to EC.

The EC skid 208 may include one or more EC reactor units 211, which maybe operable in series, parallel, or as otherwise desired. Although notlimited to any particular pressure/pressure range, any of the EC reactorunit(s) 211 may be a vessel operable to maintain pressure in a pressurerange of about 0 (atmospheric) to about 225 psi. The EC skid 208 mayalso be suitable for the destruction of pathogens, viruses, bacteria,and removes them from the fluid along with other impurities andcontaminants.

A key aspect of the EC skid 208 is the substantial reduction or outrightelimination of passivation of powered electrodes by way of introductionof a sacrificial electrode or media. The EC reactor unit 211 may haveone or more electrodes made of a durable metal, such as aluminum,titanium, silver, copper, gold, zinc, nickel, brass, iron, platinum,seal, lead, stainless steel, pure or alloys thereof, and so forth. TheEC reactor unit 211 may be configured with one or more sets ofelectrodes (e.g., cathode and anode—not shown here) that may bealternately connected to a respective positive and negative portion of acurrent source 214.

With respect to the sacrificial media (not viewable here), this may beone or more pieces formed of multivalent ion producing metal such asiron, zinc, magnesium, copper, aluminum, and so forth. The sacrificialmedia may be bipolar. The sacrificial media may be used in solid,shredded, powdered, or slurry form, and thus may be contemplated ashaving any shape suitable for facilitating EC within the unit 211.Non-limiting examples include oval, cylindrical, zig, zag, wavy, curvy,etc., and combinations thereof. Other shapes include woven metal cloth,mesh, woven metal pads, and planar and/or non-planar strips.

By using the sacrificial media, the need for removal and cleaning ofscale and other surface contaminants from the electrodes is greatlymitigated and, in some instances, even eliminated. This may provide fora dramatic increase in uptime (or rather a decrease in “downtime”) withthe corresponding decrease in operating costs. Because the sacrificialmedia may be completely consumed, there is no solid waste produced thatrequires additional handling and attention (such as is the case withspent filtration medias, the storage and disposal of which can beproblematic on an off-shore oil and gas facility).

The sacrificial media (or any piece thereof) may have a thickness in arange from about 0.1 inches to about 0.001 inches. The sacrificial mediamay be filled or otherwise disposed into a ‘cell’ region in the unit 211proximately between a respective cathode and anode. The initial fill ofsacrificial media may be about 50% to about 75% of a respective cellregion volume. In embodiments, each cell region may initially be filledto about 50% to about 75% by volume.

By positioning the sacrificial media between electrodes, the electrodesmay be spaced much further apart as compared to that of traditional EC.In embodiments, a set of a cathode and a respective anode may have anassociated separation gap distance in a range of about 3″ to about 12″.In other embodiments, the range may be about 5″ to about 7″.

It has been surprisingly discovered that this wide gap distance mayadvantageously promote use of the EC unit 211 in high capacity flow rateoperations, yet at the same time not require excessive power. It isbelieved the sacrificial media fluidized between the electrodesfunctions to reduce resistance across the fluid being treated. In thisrespect, the sacrificial media acts as a pseudo-conductivity bridgebetween electrodes. This property may further mitigate, or eveneliminate, the need for chemical additives during the EC process, andfurther promotes treatment ability of very low-conductivity waters withminimal power. The sacrificial media may be fluidized, in constantmotion, continually changing polarity, and may be further associatedwith anode/cathode spacing vastly increased over that of traditional ECtreatment systems.

This conductivity bridge is a critical difference to any other ECprocess. By engineering an effective ‘bridge’, the EC process of system200 now becomes a true commercial offering for limited space, highvolume applications where uptime is critical.

The EC reactor unit 211 may have inlet for receiving the fluid to betreated, and an outlet for the transfer of treated fluid therefrom. Theflow of the fluid through the EC unit 211 in combination with thesacrificial media may be continuous, and may result in an effectivefluidized bed where the EC process occurs. ‘Continuous’ flow throughsystem 200 may refer to the circumstance where a requisite amount ofsacrificial media has been consumed sufficiently to the point thatadditional media may need to be added to the unit 211, but furtherrecognizing that utilizing one or more skids, trains, etc. promotes theability to switch flow to another unit 211, and thus keep the processcontinuous.

Flow rates through the EC unit 211 may be in the range of about 1 gpm toabout 1000 gpm (or even greater as multiple units 211 may be utilized).Embodiments herein readily facilitate treating upwards of 35,000 BPD ofcontaminated fluid, including for offshore, at reduced weight andreduced manhours compared to that of conventional treatment systems.

Treated fluid from an outlet of the EC skid 208 may be directed to astorage tank or other operation, such as a post-EC treatment skid,whereby solids, floc, and other undesirables may be removed. Forexample, the resultant floc fluid, which may have coagulated contaminanttherewith, may be transferred to post-treatment, such as a multi-stagefloatation/defloc skid 209. Chemical injection may be used in transferbetween EC skid 208 to skid 209. A suitable chemical for injection maybe that which provides stability to the floc so that it does not readilydisassociate. A stabilizing chemical may be one that provides additionalstability to the bonds (e.g., ionic) within the floc.

To aid against passivation, the electrodes may be covered or coated withan outer surface material, which may be metallic. The outer surfacematerial may be a substantially pure noble metal, such as ruthenium.Other metals may include rhodium, palladium, silver, osmium, iridium,platinum, gold, and so forth. Also alloys of these with other metalsand/or metal oxides may be used as the outer surface coating, such asiridium oxide, titanium oxide, and ruthenium oxide may be employed withthe systems of the application. The electrode coating utilized maydepend on the treatment goal, for example, if the goal is the productionof chlorine dioxide for bacterial control, different electrode coatingsmay be selected.

It may be desirous to “flip” or reverse the polarity of the electrodesof the EC unit 211. By shifting the polarity, this may prevent or atleast mitigate the accumulation of contaminants that selectively travelin one direction within an electrical field. Switching polarity alsoprevents the buildup scale on electrode faces and maintains the‘bi-polar’ functionality of the sacrificial electrodes

The post-EC treatment skid 209 may include separate or joined flotationand filtration capability, but need not require both. In someembodiments, the flotation/dissolved gas filtration (DGF) unit 253 andthe media filtration 254 unit may be separate. The DGF unit 253 may havea single flotation zone. In other embodiments treatment skid 209 mayinclude a combined flotation and media filtration unit (for which themedia may be regenerable). In this respect, treated fluid from the ECskid 208 may enter the unit via a first inlet, and pass through one ormore floatation zones.

The zones, if more than one, may be separated by respective flowdiverters, baffles, and so forth. Gasses and some solids or phaseseparated non-aqueous fluids, to any extent present, may be collected orskimmed at the top of the inlet zone. Any of the zones may have gas, gasbubbles, microbubbles, and combinations thereof introduced (injected)therein. For example, gas and liquid may be fed to a high-shear mixer,dispersion pump, or the like, for forming a bubble-based mixture thatmay then be injected into the DGF unit 253. Injection may occur in theinlet (just prior to vessel entry), from the bottom, side, or asotherwise desired. Injection may occur via one or more injectionnozzles, which may be oriented at an angle or parallel with respect to areference axis.

The bubbles may be microbubbles (i.e., bubbles having an average bulkdiameter in micron size). Bubbles may be useful to provide buoyancy, andthus push and/or float contaminates, oil, floc, and the like to thesurface for removal, usually by skimming (skimmer not shown) orcollection in a weir or bucket for transfer via pump or pressure. Forsynergy, bubbles may be created by using gas generated in the EC unit211 to the skid 209 (and DGF unit 253).

This floatation effect may be repeated in any subsequent zones. In thelast zone, there may be an outlet in fluid communication with a mediafiltration zone, whereby the fluid may be transferred thereinto. Thefiltration zone may include compression plates, and regenerablefiltration media (not shown) therebetween. The filtration media may besuitable to effectively filter the concentration of organics and otherundesirable contaminants. The filtration media may be a compressiblemedia. Upon passing through the filtration media, the treated fluid mayexit the filtration unit via an outlet.

When in use, the filtration media may be in a compressed state. Uponsaturation, the media may be regenerated by de-compressing the mediawith the released contaminants being collected for separate disposal.This may be accomplished by back flushing with clean water, a cleaningfluid, or compressed gas such as fuel gas.

As the porosity of the compressed media diminishes, the need forregeneration increases. However, the processes of decompressing andback-flushing may allow the media to release all or nearly all of thematerials mechanically trapped therein. In embodiments there may be aporosity gradient through the compressed media. The gradient may be theresult of where compression begins—more compression where compressionstarts, less compression elsewhere. In embodiments the porosity gradientmay increase against (or be opposite to) the direction of fluid flow (orput another way, may decrease with flow). The effective pore size of themedia may be adjusted according to properties of the fluid entering thevessel. Fluid may flow through the media encountering progressively morecompressed media (with a smaller effective pore size), to removal ofsmaller and smaller contaminants. With that said, embodiments herein maypertain to fluid flow with the gradient increase.

This is step change from conventional EC, which does not utilizefiltration—conventional EC utilizes a gravity separation or a ‘floc anddrop’ concept without care about time. Moreover, filtration usedoffshore tends to be filter media, which becomes permanently saturatedwith contaminants and cannot be regenerated. This issue is veryimportant in operations such as offshore oil and gas facilities wherewaste or storage space is extraordinarily scarce, and waste such asspent filter cartridges or bulk media must instead be transported toshore and then subjected to disposal as a waste or hazardous waste.

The treatment skid 209 may be operable with one or more units inparallel, series, or otherwise as desired. Operating in series mayprovide for differential filtering whereby the amount of compression maybe varied to control the size of particles that may pass through thefilter media. In an embodiment, the media in a first media filter unitmay be compressed such that comparatively large particles may be caught,and fine particles may be passed through to a second media filter unit,whereby the media is further compressed to catch the fine particles.

Fluid exiting the treatment skid 209 may be passed through a monitoringunit 223, which may include a controller operable with one or more(sub)systems to determine fluid quality. Treated fluid (or systemproduct) 285 may be readily discharged or transferred from the system200.

If the fluid quality leaving the system 200 is within a presetspecification, the now treated fluid 285 may be disposed, such as viapump or gravity, through a discharge line (such as dischargingoverboard). Fluid that does not meet spec may be recycled through thesystem 200, such as via a recycle header, and back to any portion ofsystem 200.

The system 200 may include a power distribution unit (PDU) 255 that maybe operable and coupled in a manner to provide power to every equipment,skid, component, subsystem, etc. of system 200 (power leads not shownfor brevity). The PDU 255 may be standalone, or may be able to interfacewith a source power unit 284. The system 200 may include capability toprovide one or more of power conversion, power control and/or powermanagement.

Controlling power and/or energy may be important in both for maintainingquality as well as managing energy expenditures related to system 200and embodiments disclosed herein. In some embodiments, power may becontrolled using at least one property of at least one of the feedfluid, in system fluid, and effluent fluid.

Power for the systems of the disclosure may come from any suitablesource. For example, the source power unit may be a commercial electricservice provider or in other embodiments, it may be from a customer'smaster control center (MCC), solar array, battery bank and generator setcapable of providing for at least critical loads. The PDU 255 may havevarious components, such as a fan, DC power converter, PC power and sitecontroller, transformers, container lights, electric pump, fuel pump,fire extinguishing system, AC unit, automation system, safety systemcontrol, interface with source control and safety system, sensorsurveillance and camera system and components for communication.

The PDU 255 may be operable to monitor loads the system 200 andauto-manage multiple energy sources. The PDU 255 may be equipped withcontrols that regulate the distribution of power sources relative to thecritical or non-critical nature of the loads and the system 200. Loadsof the system 200 may include any piece of equipment, associatedlighting, or other devices not described, but otherwise apparent to oneof skill in the art.

The PDU 255 may also be used to control operational aspects of thesystem 200. For example, in one embodiment, the system 200 may employone or more sensors capable of measuring pH, oxidation-reductionpotential (ORP), LEL, temperature, and conductivity. By using thesecomponents, the system 200 itself may be regulated to operate with moreefficiency. For example, less voltage (or more importantly, less power)may be employed in applications where the fluids being treated haverelatively higher conductivity. In another example, pH can be monitoredto mitigate the use of chemical additives, and in yet anotherembodiment, ORP may be monitored to optimize consumption of electrodesand/or the sacrificial media.

In some embodiments, the system 200 may include an oil and greasesensor. In still other embodiments, this sensor may be employed tooptimize operation of the system.

Referring now to FIG. 3, an isometric view of customer interface system,in accordance with embodiments disclosed herein, is shown. FIG. 3illustrates a customer interface system (CIS) 301 usable with system andprocess embodiments described herein.

Embodiments herein apply to a CIS that may be an inclusive assembly of anumber of components, subcomponents, which may be further associatedwith operable systems, subsystems, assemblies, modules, skids, and soforth, including those described herein. While CIS 301 may be shown as a‘skid’ for simplicity, components of the CIS 301 need not be skidmounted. The CIS 301 may be part of an overall treatment system, such assystem 200. While it need not be exactly the same, CIS 301 may includevarious features and components like that of other systems or unitsdescribed herein, and thus components thereof may be duplicate oranalogous.

The CIS 301 may be configured to interface or couple with a unit,operation, system, etc. whereby an incoming fluid from a source orsource operation (not shown here) may be fed to the CIS 301, such as viaa connecting between feedline (e.g., 203, FIG. 2) and a CIS inlet 302.The CIS 301 may provide desired pressure and flow control into thetreatment system (200). The source operation may occur on or beassociated with an offshore vessel, such as an FPSO. Of significance,the CIS 301 may be configured to provide shutoff or disconnect abilityto the system (200).

The CIS 301 may have various valves, flanges, pipes, pumps, utilities,monitors, sensors, controllers, safety devices (such as pressure safetyvalves (PSVs), isolation valves, shutdown valves, flow control valves,pressure gauges, and so forth), chokes or pressure reducer valves, flowmeters, etc., for sufficient universal coupling to any applicablefeedline/feed source of a fluid to be treated from a source operation.The CIS 301 may be in fluid communication with a wellbore, wellhead,tank, pipeline, subsea flowline, etc. associated with the sourceoperation. The CIS 301 may have a monitor operable to ensure the fluidstream is suitable for system treatment. The CIS 301 may have a returnor bypass line 304 for in the event the fluid stream may be deemedunsuitable, and thus the fluid stream transferred elsewhere.

The CIS may include fluid analyzer (such as an oil and water analyzer)326. The analyzer 326 may be operably associated with a valve whereby ifa predetermined threshold or specification is not met, fluid may bebypassed or prevented from entering the treatment system. The CIS 301may thus be configured to control (or de-rate) flow, or otherwise exportdata to a control system for the same. In this respect the CIS 301provides a fluid quality control check for the system (200), as well astrack historical data.

Fluid coming into the CIS 301 may have an initial pressure of about 50psi to about 2200 psi. In embodiments the initial pressure may be in therange of about 80 psi to about 450 psi. Fluid coming into the CIS 301may have an initial temperature of about 50° F. to about 175° F.Generally, the fluid coming into the CIS 301 may be predominantlyliquidious. Although not meant to be limited, the fluid may be in therange of about 90% to about 100% by weight liquid phase. The fluidcoming into the CIS 301 may have a high degree of solids, such as 2000to 3000 ppm TSS, but in some instances even upwards of 2% TSS (or 20,000ppm TSS). With a higher solids content, the flow rate may be reduced.

Fluid deemed suitable for treatment may be transferred from the CIS 301downstream via outlet 324. In embodiments, fluid may be transferred fromthe CIS 301 to a pre-treatment skid, depressurization skid, EC skid, orother operations of the fluid treatment systems described herein. Inthis respect fluid introduced into the system (200) need not go throughthe CIS.

Referring now to FIGS. 4A and 4B together, a side cross-sectional viewof an EC unit coupled with a rectifier, and an isometric view of an ECunit with an inner housing, respectively, in accordance with embodimentsdisclosed herein, are shown.

FIGS. 4A and 4B together illustrate an EC unit 311 usable with systemand process embodiments described herein. The EC unit 311 (and rectifier314) may be part of an overall EC skid 308. Embodiments herein apply tothe EC skid 308 that may be an inclusive assembly of a number ofcomponents, subcomponents, etc. which may be further associated withoperable systems, subsystems, assemblies, modules, skids and so forth,including those described herein. In embodiments there may be a singleor a plurality of EC units 311 and associated rectifiers 314. The skid308 may be operable in series, parallel, or as may otherwise be desired.

The EC unit 311 may be mounted to a frame-type structure 338 via one ormore legs 336 or support mounts 336 a. As shown in FIG. 4B, the EC unit311 may be mounted to or otherwise positioned on a flooring 343. It isnoted that while the EC unit 311 may be referred to as part of a ‘skid’for simplicity, components of the EC skid 308 need not be skid mounted.The EC unit 311 may be part of an overall treatment system, such assystem 200. While it need not be exactly the same, EC skid 308 mayinclude various features and components like that of other systems orunits described herein, and thus components thereof may be duplicate oranalogous.

The EC unit 311 may be configured to interface or couple with a unit,operation, system, etc. whereby an incoming fluid from, for example, asource operation, a pre-treatment vessel or skid, or a CIS (301, FIG. 3)may be received. Fluid F_(i) may be received into the EC unit 311 via aninlet 316, and upon treatment, may leave the EC unit via an outlet 317as a ‘treated fluid’ F_(o). While shown as side in, top outconfiguration, other fluid entry/egress points are possible, such as onthe bottom and/or sides of the unit 311.

One of skill in the art would readily appreciate that typical EC occursin an open or atmospheric system, and as such unit 311 may be operablecomparably thereto. However, the EC unit 311 may be configuredtantamount to an ANSI pressure vessel, which is to say the EC unit 311may be run under pressure. The EC 311 unit may comfortably operate inpressure ranges from 0 psi to 225 psi. In embodiments the operatingpressure of the EC unit 311 may be about 50 psi to about 160 psi. The ECunit 311 outer shell 330 may be made of a durable material, such asstainless steel, carbon steel, fiber glass, etc.

A key aspect of the EC skid 308 is the substantial reduction or outrightelimination of passivation of powered electrodes by way of introductionof a sacrificial electrode or media 340. Thus, the EC unit 311 may havea sacrificial or consumable media 340 filled or otherwise disposedtherein.

The EC unit 311 may have one or more electrodes 312 made of a durablemetal, such as aluminum or titanium, or any suitable noble metal. The ECunit 311 may be configured with one or more sets of electrodes 312 thatmay be alternately connected to a respective positive 313 a and negativeportion 313 b of a current source, such as the rectifier 314 (via twobusbar conductors 334—one connected to positive, one connected tonegative). Although embodiments herein refer to a busbar 334 (typicallyrigid), other ways of transferring current to the electrodes may beused, such as flexible cabling.

With respect to the sacrificial media 340, this may be one or morepieces formed of multivalent ion producing metal as described herein.The sacrificial media may take any shape suitable for facilitatingelectrocoagulation within the unit 311.

Referring briefly to FIGS. 5A-5E, a side view of a wavy media, a sideview of a loose spiral media, a side view of a tight spiral media, aside view of a curved media, and a side view of a combinationlinear-curvilinear media, respectively, in accordance with embodimentsdisclosed herein, are shown.

FIGS. 5A-5E readily depict a sampling of shapes for use as thesacrificial media 540 a-e. Other non-limiting examples include oval,cylindrical, zig, zag, wavy, curvy, spiral, twisted, crescent, balls orspheres, symmetrical, non-symmetrical, etc., and combinations thereof.Other shapes include woven metal, cloth, mesh, woven metal pads,sheeting, and planar strips. The sacrificial media may include one ormore perforations (such as shown in FIG. 5A) to facilitate quickersurface contact with the fluid, and thus an increase in efficiency ofmedia consumption. The use of perforations may also prevent thepocketing or collecting of gas against irregular shape.

Although not meant to be limited, sacrificial media of the presentdisclosure may have an effective shadow foot print of about 1″×1″ toabout 6″×6″. In generally, the largest dimension across the sacrificialmedia may be less than the distance of the electrode spacing gap (315).Were the dimension to be larger, then the greater chance of apseudo-short circuit within a particular EC cell (341) by way of directcontact end-to-end between the media the respective electrodes, which isundesired.

In embodiments there may be a trough 541 a and a crest 541 c, with anamplitude A therebetween (with one or more perforations 557). Inembodiments, there may be about 2 to about 4 rows of perforations, eachrow having about 2 to about 7 perforations. Because of the additionalsurface of the media 540 a, there is more surface area of the mediaversus an effective shadow foot print area. By way of an example, a3″×3″ piece, with an amplitude (or height) A of about 0.5″ may have asurface area of 15″ (thus flattened may be about 5″×3″), whereas theshadow foot print is 9″. The more surface area per volume of sacrificialmedia, the more media that can be used, and thus the replacement cycletime increased. In cross-section, the media 540 a may be curvilinear(including a radius at the trough(s) and crest(s)).

The size and volume of sacrificial media may be selected to synergizefluid flow and reaction. Too little or small (or too compacted) mediamay reduce the reaction ability (or conductivity bridge), whereas toomuch or too large of media may impede fluid flow rates.

The sacrificial media (or any piece thereof) may have a thickness in arange from about 0.1 inches to about 0.001 inches (including alldimensions in between), and the thickness may be uniform (orsubstantially uniform with known tolerances) or may have variation. Inembodiments, the thickness of the sacrificial media may be about 0.001″to about 0.005″.

The sacrificial media may be filled or otherwise disposed into a ‘cell’region in an EC unit (311) proximately between respective electrodes.The volume of any given cell may be filled with about 50% to about 75″of sacrificial media.

Returning again to FIGS. 4A-4B, it is worth noting that the sacrificialmedia need not be uniform whereby different shapes and sizes, withdiffering dimensions, may be used simultaneously. As the sacrificialmedia 340 may be consumed, the EC unit 311 may be configured for easyaccess so replacement media may be filled or otherwise disposed therein.Thus, the unit 311 may have a first portion 328 a, such as a top or lid,sealingly, but releasably, engageable with a bottom portion 328 b. Thefirst portion 328 a and second portion 328 may be releasably coupledtogether in any suitable manner, such as via nut and bolt. Foradditional convenience, the EC unit 311 may be configured with a davitarm assembly 327. One of skill would appreciate that the davit armassembly 327 may make it easy to lift and separate the first portion 328a from the second portion 328 b. Moreover, the assembly 327 may providea pivot point, whereby the first portion 328 a may be sufficiently movedout of the say so that media 340 may be properly replaced into the ECunit 311.

The entire process of opening, replacing, and sealing may take about 5minutes to about 10 minutes, which is a remarkable improvement totraditional electrode replacement. This may further include switchingfrom a first train to a second train (i.e., a second or redundant ECunit) of the EC skid 308, as well as depressurizing, draining, and/orpurging (such as with N2) the EC unit 311. It is anticipated thatreplacement cycle for sacrificial media may be on the order of hours,such as once per shift, or even once per 1-2 days, or longer dependingquality and constituent make-up of fluid being treated.

Because the EC unit 311 may be pressurized, the unit housing (or outershell) 330 may be metallic. In order to avoid or prevent conductingelectricity to the housing, the unit 330 may be lined with an insulator,or grounded. The unit 311 may have one or more inner housings 329disposed therein. The inner housing 329 may be made of a non-conductivematerial, such as polypropylene, fiberglass, carbon fiber, and so forth.

As shown here the unit 311 may be generally cylindrical in shape, andthe inner housing 329 may be generally rectangular prism (or box) inshape, however, embodiments herein are not meant to be limited and othershapes are possible.

Referring briefly to FIGS. 4C and 4D together, a partial sidecross-sectional view of an inner housing disposed within an EC unit, anda downward view of a perforated insert for the EC unit of FIG. 4C,respectfully, in accordance with embodiments disclosed herein, areshown.

FIG. 4C shows the EC unit 311 may include the annular ring mount 382mounted or otherwise extending inward from an inner wall 330 a. The ringmount 382 may be integral or otherwise connected, welded, etc. with theinner wall 330 a. The ring mount 382 provides additional stability tothe housing 329 (or lip 386) via a mount connection point 390therebetween. As the EC unit 311 may have continuous fluid flowtherethrough, including at high rates, it may be useful to providestabilization to the housing 329. A bottom 335 of the housing 329 mayhave one or more perforations (including a plurality of perforations)357 b to accommodate fluid flow through the unit 311.

A top or upper region of the housing 329 may be open. However, it may beeasier to maintain sacrificial media within the cells (betweenrespective electrodes 312) by using one or more perforated inserts 358.The perforated insert 358 may have a plurality of perforations 357 c.The inserts 358 may be sized to fit within the space between eachadjacent electrodes and respective sidewalls of the housing 329. Inembodiments, there may be two half-size inserts 358 for each respectivecell tantamount to the insert 358 shown in FIG. 4D being cut in half.

To maintain the position of the perforated inserts 358, they may becoupled with the sidewalls of the housing 329. In addition, or in thealternative, a retention member (see cover plate 356A, FIG. 4B) may beused. In addition to a releasably attachable cover plate, other means ofretention are possible, such as a retention bar extending longitudinallyfrom one end of the housing 329 to the other. The retention member maycouple along one or more points of the inner housing mount ring 382. Inthe event of multi-piece insert is used, there may be multiple retentionmembers. The retention member may be non-conductive.

The inner housing 329 may include another grate or junk trap 358 a(which may be perforated. The bottom 335 or the grate 358 a may beconfigured with a groove (or ‘u’, v-notch, etc.) 383 for which arespective bottom of the electrode 312 may fit therein. In this respect,load from the electrodes (which may each have a weight in a range ofeven greater than 50 lbs) may be supported by the inner housing 329and/or the outer vessel 330. In this respect, load may be removed fromthe busbar (334). Moreover, the electrodes 312 may be more readilymaintained in position (whereas if just ‘hanging’ be more susceptible toinadvertent movement).

There may be a partition 337, which may be positioned at an approximatemidpoint in the inner housing 329. The partition 337 may be made of aninsulating material, such as a plastic. The use of the partition 337 maybe useful to control power distribution from the busbar 334 to theelectrodes 312.

Returning again to FIGS. 4A and 4B, the electrodes 312 may each have anassociated surface area. The use of inner housing 329 may be suitable toensure the surface area of respective electrodes 312 may be uniform. Itis worth noting that the respective electrode shapes may each vary, yetstill have uniform surface area. Moreover, although shown here asgenerally rectangular planar plates, the electrodes 312 may have othershapes, including non-planar (i.e., with curvature).

As one of skill may appreciate, typical EC utilizes a ‘dry’ connection.That is, power is connected to a dry portion of an electrode open to thesurrounding air/atmosphere, with the remaining portion being submergedin the fluid. Embodiments herein provide for not only a dry connection,but also a ‘wet’ connection, which may be particularly useful for an ECreaction under pressure. The ability to operate ‘wet’ may be ofsignificant importance for O&G operations, and particularly offshore O&Goperations, where stringent HAZLOC requirements and/or other rules andregulations must be met.

A wet connection may allow for greater temperature control and avoidundesired energy loss that may normally be associated with a dryconnection. Energy loss from heat buildup equates to power loss, andthus less current transfer, greater chances of passivation, andultimately reduced ability for agglomeration of contaminants and/oremulsion breaking.

A wet connection may further allow operation of the EC unit 311 underpressure, mitigation or elimination of safety concerns associated withdry operation “headspace”, and mitigation or elimination of pumping ofEC fluid which not only eliminates a pump(s) but maintains thecoagulated state of the floc and pollutants. That is, putting coagulatedfloc through a pump may tear up or destabilize the floc, which wouldrequire either time or chemical to make the floc re-coagulate (thus asignificant reduction, an elimination of chemical addition, and/orimproved effluent quality).

Operating under pressure may enable EC-generated gases to break out inany downstream flotation unit, and thus be used as a source for(micro)bubble generation and enable excess gases to be transferred to LPflair systems at the end of the process instead of venting to a “safe”area. Venting on an offshore facility is a risk, “safe” area or not,therefore operating the EC under pressure reduces operational risks.Moreover, many operations associated with O&G operations are known to bepressurized for numerous reasons. In this respect, fluid F_(i) maycontinuously flow freely through the unit 311 (including through theinner housing 329 and related cells 341 (volume of space betweenadjacent electrodes), as well as in contact with the sacrificial media340 and busbar(s) 334). In embodiments the EC unit 311 may besubstantially liquid flooded and pressurized.

The busbar 334 may be a conducting coupler type piece suitable fortransferring power (current) from a power supply or rectifier into theEC unit 311, and to the electrodes. Although the busbar 334 may begenerally planar or rectangular prism in shape, embodiments herein arenot meant to be limited, and other busbar shapes are possible, such astubular, cylindrical, or oval (in cross-section), elliptical (incross-section), and may be non-symmetrical. It is within the scope ofthe disclosure that the busbar 334 for the negative side may be the sameor may be different from that of the positive side.

Further consideration is required for the circumstance when the EC unit311 may be operated under pressure, as the busbar 334 must be coupled ina manner that does not result in the outer housing 330 beingelectrified. Thus, a pressure gland assembly 333 may be used (for eachof the positive and negative sides). The pressure gland 333 may includea gland body 344 encapsulated or otherwise sealingly disposed around atleast a portion of a gland power bar 347.

A portion 350 of the gland 333 may be sealingly compressed between facesof respective flanges 325, 332. The flange 325 may be part of a spoolpiece 342 coupled between the gland assembly 333 and the rectifier 314.The spool piece 342 may be coupled to the rectifier at connection point331. Naturally there may be two spool pieces 342, one for each of thepositive and negative sides. In embodiments, the spool piece may not benecessary, and a compressing flange face or other suitable structure maybe suitable.

The gland power bar 347 may be coupled to the busbar 334 in a manner sothat it may be isolated from any contact with connection flanges 332 (a,b) of the EC unit 311, respectively. The gland 333 may be configured tomaintain pressure of the EC unit 311 even though the power bar 347 maypass or be encapsulated therein. On the other side, the gland power bar347 may be coupled to a rectifier power bar 351, which then itself iselectrically coupled within the rectifier 314.

Although described herein as ‘bars’, and contemplated as rigid, otherembodiments are possible, whereby any of the rectifier bar 351, glandpower bar 347 and/or busbar 334 may be flexible, such as cabling(braided wire and so forth). Moreover, the geometry of any ‘bar’ is notmeant to be limited, as other shapes may be possible, such as circular,helical-wound, zig-zag, curvilinear, and others.

As industrial convention typically requires rounded or circular flangefaces, it may be further the case that the gland assembly 333 may needto be shaped correspondingly. Referring briefly to FIGS. 6A, 6B, and 6Ctogether, an isometric view of a pressure gland assembly, a partial sidecross-sectional component breakout view of a pressure gland assemblyassociated with an EC unit and a spool piece, and a partial sidecross-sectional assembled view of the components of FIG. 6B,respectfully, in accordance with embodiments disclosed herein, areshown.

The gland assembly 633 may be suitable for use in a fluid treatmentsystem, such as system 200. While it need not be exactly the same, thepressure gland assembly 633 may include various features and componentslike that of gland 333 or other units described herein, and thuscomponents thereof may be duplicate or analogous.

The gland 633 may have a main gland body 644, which may be generallycylindrical. One of skill would appreciate the gland 633 may be amulti-part device that may include the gland body may be formed orotherwise molded, encapsulated, etc. around a gland power bar 647 (thegland power bar 647 being suitable for conducting power into an EC unit(611—partial view, or see 311, FIG. 4B) via coupling with busbar 634.The size of the gland assembly 633 may be a function of how much powertransfer is required. Thus, more power may mean a bigger bar 647, whichmay mean a bigger gland body 644.

FIG. 6B illustrates the gland power bar 647 being separately viewablefrom the gland body 644, thus revealing what may be tantamount to agland opening or passageway 645. The gland body 644 may be bonded(mechanically or chemically), molded, epoxification, fused, glued,cured, etc. with the gland power bar 647, or any other type ofconnection whereby the gland assembly 633 may be able to withstandpressure. In embodiments, the gland 633 may be rated to withstandupwards of 225 psi. The main gland body 644 may be made of rubber,plastic, composite, or comparable compressible material suitable formaintaining a pressure seal.

The body 644 may have an effective outer diameter suitable to conformwithin whatever piping, conduit, etc. may be coupled with the assembly633. For a non-limiting example of scale, in embodiments, the outerdiameter of the body 644 may be about 1″ to about 8″. The length of thepower bar 647 may be configured to accommodate whatever distance may beneeded to couple the rectifier (314) with the EC unit (311).

Any bar or other conducting component external to the EC unit (311) maybe copper, Ti clad copper (or other conductive material), may have asurface coating. Any bar or other component exposed to fluid flow withinthe EC unit may also be Ti clad copper (or other conductive material),may have a surface coating. In this respect, the busbar 634 as well asone of the ends of the gland power bar 647 may be coated with a highlyconductive material (such as platinum) for the metal-to-metalconnection, whereas remaining areas exposed to liquid may be coated witha dielectric insulator, such as Plastisol.

There may be an outer lip or sealing surface 650 that may be integral orotherwise coupled to the gland body 644. Although not meant to belimited, the outer lip 650 may be formed as an annular bulge around anapproximate mid-point of the gland body 644.

As one of skill would appreciate the gland body 644 may be configured,shaped, sized, etc. for either end to fit within respective flanges 625,632 (of respective piping, spool piece, etc.). In a similar manner, thelip 650 may be configured, shaped, sized, etc. for compressing,squeezing, etc. between faces of the respective flanges 625, 632.Accordingly, the gland body 644 and the slip 650 may be generallycylindrical (and round in lateral cross-section). The lip 650 may havean effective lip outer diameter of suitable length to form the desiredsealing between the flanges 625, 632. In a non-limiting example, the lipouter diameter may be about 2″ to about 10″.

The flanges 625, 632 and the lip 650 may be configured with various(alignable) eyelets, holes, etc. 646 a for respective fasteners (e.g.,nut-bolt, etc.) 649 a to pass therethrough for securably coupling. In asimilar manner the gland power bar 647, the rectifier power bar 651, andthe busbar 634 may be configured with various (alignable) eyelets,holes, etc. 646 b for respective fasteners (e.g., nut-bolt, etc.) 649 bto pass therethrough for securably coupling. Other fastenerconfigurations are possible, such as magnets or clips.

Returning again to FIGS. 4A and 4B, although the electrodes 312 areshown as disposed within the inner housing 329, the EC unit 311 is notlimited to requiring such. Thus, it may well be the case that theelectrodes 312 may be positioned within the unit 311 itself, which maybe the case when the unit 311 may be configured with an inner insulator(such as on the inner walls). Although not necessary, the electrodes 312may each have a generally similar shape for uniformity purposes.Similarly, although there may be variation, respective electrodes 312may have an electrode gap 315 therebetween.

The electrodes 312 may be coupled with the busbars 334 in an alternatingmanner. That is, a first electrode (from left to right) 312 may becoupled with the busbar 334 on the positive side at first connection 313a. Although not necessary, the first connection 313 a may include ajumper 339 coupled between the busbar 334 and the electrode 312. Thesurface area between a jumper/electrode connection may be that for whichpromotes the best current transfer and distribution through the unit311. The jumper 339 may have an associated surface area, as well as acontact (or connection) surface area with that of the electrode 312. Inembodiments, the connection surface area between the jumper 339 and theelectrode 312 may be about 1 in² to about 6 in². The connection areabetween respective jumpers and electrodes may be substantially similar.

The second or next electrode 312 may be coupled with another busbar 334on the negative side at second connection 313 b. This pattern may repeatitself as may be applicable to the number of electrodes utilized, whichmay vary. In embodiments there may be between about 1 to about 14electrodes. In other embodiments there may be about 6 electrodes toabout 10 electrodes.

As described herein the busbar(s) 334 may be subjected to continuousliquid flow which may require consideration for mitigation or preventionof effects from electrolysis and deterioration.

Referring briefly to FIGS. 7A, 7B, and 7C, together, a partial sidecross-sectional view of a coated busbar coupled with a coated electrode(with a coated jumper therebetween), a close-up cross-sectional view ofthe coupled components of FIG. 7A, and a component view of a flexiblejumper, respectively, in accordance with embodiments disclosed herein,are shown.

The electrode 712 may have a main body 712 a that may be made of adurable material suitable for the transfer of current, such as a metallike titanium, stainless steel, iron, copper, etc. Because the electrode712 is not meant to be ‘sacrificed’, it may be useful to use a coatingto extend the longevity of the electrode life. To aid againstpassivation, the electrode 712 may be covered or coated with an outersurface material (or just ‘coating’) 760, which may be metallic. Theelectrode 712 may have a thickness T_(E) of about 0.1″ to about 2.5″.

The electrode 712 may have an associated surface area. The electrode mayhave a cumulative (e.g., each side for a planar shape) electrode surfacearea in the range of about 1,000 in² to about 2,000 in². In embodiments,each of the one or more electrode(s) (including all) 712 disposed withinan EC unit (312) may have a cumulative (e.g., each side for a planarshape) electrode surface area in the range of about 1,000 in² to about2,000 in², where the total electrode surface area within the unit (312)may be in a range of about 10,000 in² to about 20,000 in². As anon-limiting example, the electrode 712 may be rectangular in shape witha size of about 20″×40″ (with a thickness T_(E) of about 0.25″).

The electrode coating 760 may be a substantially pure noble metal, suchas ruthenium. Other metals may include rhodium, palladium, silver,osmium, iridium, platinum, gold, and so forth. Also alloys of these withother metals and/or metal oxides may be used as the outer surfacecoating, such as iridium oxide, titanium oxide, and ruthenium Oxide maybe employed with the systems of the application. The use of the coating760 may add substantial longevity to the life of the electrode 712. Theuse of the coating 760 may also facilitate better gas (e.g., O2, H2,etc.) production or targeted pollutant mitigation.

The busbar 734 may be have a protective busbar coating, whereby the mainbody 734 a of the busbar 734 may be a conductive metal, such as copper,titanium, stainless steel, iron, or an alloy titanium clad copper (e.g.,Ti-Clad CU, Ti/Cu, TiCladCu, etc.). The busbar coating may be multi- ordual-layered. As shown in FIG. 7B, a first portion of the main body 734a may be coated with a dielectric non-conductive coating 792, such asPlastisol. However, a second portion of the main body 734 a may have aconductive coating 793. The conductive coating 793 may be any coatingmaterial suitable for good metal-to-metal conductivity, such asplatinum.

In a similar manner, the jumper 739 may be subjected to continuousliquid flow thus prompting likeminded consideration. Thus, the jumper739 may be have a protective jumper coating, whereby the main jumperbody 739 a of the jumper 739 may be a conductive metal, such as copper,titanium, stainless steel, iron, or alloy such as titanium clad copper(e.g., Ti-Clad CU, Ti/Cu, TiCladCu, etc.).

The main body 739 a may then have a jumper coating. The jumper coatingmay be multi- or dual-layered. As shown in FIG. 7B, a first portion ofthe main body 739 a may be coated with a dielectric non-conductivecoating 792, such as Plastisol. However, a second portion of the mainbody 739 may have a conductive coating 793. The conductive coating 793may be any coating material suitable for good metal-to-metalconductivity, such as platinum.

The electrode 712 may be suitable for use in a fluid treatment system,such as system 200. While it need not be exactly the same, the electrodemay include various features and so forth like that of electrode 712 orother electrode units described herein, and thus may be duplicate oranalogous.

FIG. 7A illustrates the busbar 734 may be coupled with the electrode 712via a jumper 739, as further described herein. Although not shown here,the busbar 734 may be coupled directly to the electrode 712.

The jumper 739 may be any suitable shape and material for transferringcurrent from the busbar 734 to the electrode 712. In this respect, arigid L-shape jumper 739 may be suitable. However, there may beinstances that require more flexibility, for which FIG. 7C illustrates aflexible jumper 739 b (made of braided wire or other suitable fashion toprovide flexibility, twisting, and bending).

Returning again to FIGS. 4A and 4B, by positioning the sacrificial media340 between electrodes 312, the electrodes 312 may be spaced muchfurther apart as compared to that of traditional EC. In embodiments, aset of a cathode and a respective anode may have an associatedseparation gap distance 315 in a range of about 3″ to about 12″. Inother embodiments, the gap 315 may be in the range of about 5″ to about7″. A wide gap distance may advantageously promote use of the EC unit311 in high capacity flow rate operations, yet at the same time notrequire excessive power normally required for conventional EC. As anillustrative example, a conventional EC unit may need to be operated at110 volts to accommodate gap distance, whereas the EC unit 311 may beoperated at 10 volts for the same. In embodiments the voltage range maybe about 1 volt to about 20 volts.

It is believed the sacrificial media 340 fluidized between theelectrodes 312 may function to reduce resistance across the fluid beingtreated. In this respect, the sacrificial media 340 acts as apseudo-conductivity bridge between respective electrodes 312, which maybe attributable to the reduced power requirement, and further mitigate(or even eliminate) the need for chemical additives during the ECprocess.

Rectifier 314 may be configured to convert or interface utilityelectricity to DC, such as that received from a power source (284, FIG.2). The rectifier 314 may be a protectively sealed unit, which may haveinternal cooling such as with oil or air (or other non-conductivemedia). Although not shown here, the rectifier 314 may have a couplermount, which may be internal (not viewable here). The coupler mount maybe planar or have a planar surface for suitable coupling to a rectifierpower bar 351. As one of skill would appreciate the rectifier 314 mayhave two separate interface coupler mounts, one for a ‘positive’ side,and one for a ‘negative’ side. Thus, the rectifier 314 may be configuredin a manner for easy transfer of power therefrom to the EC unit 311.

In embodiments the rectifier 314 may provide a voltage in a voltagerange of about 35 V to about 150 V. The voltage may be in a lower rangesuch as about 1 V to about 20 V. The rectifier 314 may provide currentin a current range of about 200 A to about 2000 A. In embodiments, thecurrent range may be about 300 A to about 500 A. The rectifier 314 mayreceive power (directly or indirectly) from a regulated utility, acommercial provider, or a local source, such as a MCC (255), and thelike.

During the operation of the unit 311, coagulation of solids, oils, andother contaminants results in generation of the floc. In a continuousoperation, this may be ongoing with a limited residence time of about 10seconds to about 45 seconds. The operation of the unit 311 may alsoresult in generation of gas bubbles. The floc and the gas bubbles mayflow or otherwise be directed to a respective outlet.

The EC unit 311 may have inlet 316 for receiving the fluid to betreated, and an outlet 317 for the transfer of treated fluid therefrom.The flow of the fluid through the EC unit 311 in combination with thesacrificial electrode may be continuous, and may result in an effectivefluidized bed where the EC process occurs. Flow rates through the ECunit 311 may be in the range of about 1 gpm to about 1000 gpm. In anembodiment the flow rate may be about 200 gpm to about 500 gpm.Embodiments herein readily facilitate treating upwards of 35,000 BPD ofcontaminated fluid, including for offshore, at reduced weight andreduced manhours compared to that of conventional treatment systems.

Treated fluid from an outlet of the EC skid 308 may be directed to astorage tank or other operation, such as a post-EC treatment skid,whereby solids, floc, and other undesirables may be removed. Forexample, the resultant floc fluid, which may have coagulated contaminanttherewith, may be transferred to post-treatment, such as a multi-stagefloatation/defloc skid (309). Chemical injection may be used in transferbetween EC skid 308 to the next skid. A suitable chemical for injectionmay be that which provides stability (e.g., bond strengthening) to thefloc so that it does not readily disassociate. The chemical may bepolymeric in nature or be a polymeric blend.

It may be desirous to “flip” or reverse the polarity of the electrodesof the EC unit 311. By shifting the polarity, this may prevent or atleast mitigate the accumulation of contaminants that selectively travelin one direction within an electrical field.

Referring now to FIGS. 8A and 8B together, a partial internal side viewof a dissolved gas floatation (DGF) vessel of a DGF skid, and a partialinternal side view of a compressed media vessel of a filtration skid,respectively, in accordance with embodiments disclosed herein, areshown.

FIGS. 8A and 8B together illustrate a DGF skid 809 a and a filtrationskid 809 b usable with system and process embodiments described herein.The DGF vessel 853 may be part of the DGF skid 809 a. Embodiments hereinapply to the DGF skid 809 a that may be an inclusive assembly of anumber of components, subcomponents, etc., which may be furtherassociated with operable systems, subsystems, assemblies, modules,skids, and so forth, including those described herein. In embodimentsthere may be a single or a plurality of DGF vessels 853. The skid 809 amay be operable in series, parallel, or as may otherwise be desired.

In a similar fashion the filtration vessel 854 may be part of thefiltration skid 809 b. Embodiments herein apply to the filtration skid809 b that may be an inclusive assembly of a number of components,subcomponents, etc., which may be further associated with operablesystems, subsystems, assemblies, modules, skids, and so forth, includingthose described herein. In embodiments there may be a single or aplurality of filtration vessels 854. The skid 809 b may be operable inseries, parallel, or as may otherwise be desired.

It is noted that while the either of the DGF vessel 853 or thefiltration vessel 854 may be referred to as part of a ‘skid’ forsimplicity, components of either skid need not be skid mounted. Thevessels 853, 854 may be part of an overall treatment system, such assystem 200. While they need not be exactly the same, vessels 853, 854may include various features and components like that of other systemsor units described herein, and thus components thereof may be duplicateor analogous.

Generally, there need not be any reject or bypass of outflow from ECunit operations described herein, so all (or substantially all) of theoutflow (including gas, bubbles, liquid, and floc) from a respective ECunit (311) may be provided to the DGF vessel 853 (or optionally thefiltration vessel 854). Thus, a fluid F_(i1) may be fed or otherwisereceived into the DGF vessel 853 via DGF inlet 863. The skid 809 a mayinclude an injection system 899. Dissolved gas or bubbles feed stream822 a may be introduced into the fluid inflow and/or into vessel 853,such as via one or more injection points 867. Other forms of gas/bubblesintroduction may be used, such as induced gas flotation (IGF).

As shown here, the injection system 899 may include a dispersion formingmember 887 in fluid communication with various source streams anddischarge (or injection) points associated with the vessel 853. Themember 887 may be a high-shear mixer, dispersion pump, or any otherdevice suitable for forming a bubble-based mixture that may then beinjected into the DGF unit 853.

The injection points 867 (with respective nozzles or ports) may belocated at various points on the vessel 853, such as at the bottom, theside, and combinations. For a synergistic advantage, gas generated(produced) in the EC unit (311) may be used for injection. However,other gas sources may be used, including gas from overheads 889 (via gasoutlet 889 a). In a similar manner, treated water 888 from any unitdescribed herein may be used; however, other water or liquidous sourcesmay be used. An injection stream 822 a may be created by drawing fluidsand/or liquids varied sources, such as a pressurized tank.

The dissolved gas within the stream 822 a may be O2, O3, H2, air, or anysuitable gas for prompting floatation. Although shown here as vertical,the DGF vessel 853 may have other orientations, such as horizontal. TheDGF vessel 853 may be operated at atmospheric or pressurized conditions.The stream 822 a may include microbubbles having an average bulkdiameter of about 10 microns to about 300 microns. In some embodimentsthe microbubbles may be smaller with an average diameter of about 10microns to about 30 microns. In other embodiments the microbubbles maybe larger with an average diameter of about 200 microns to about 300microns. The stream 822 a, upon release into the vessel 853, may resultin gas bubbles 822 released from dispersion.

During operation the vessel 853 may have a discernable liquid leveldifferentiated by water versus that of floc 818. The vessel 853 may havean oil bucket or weir-type structure 866 for capturing floc, oil, etc.818. The floc 818 (or F_(L)) may exit the vessel 853 via overhead outlet865, and transferred therefrom. The DGF vessel 853 may have bottomoutlet 864 for which separated/treated fluid F_(o1) may exit therefrom.The outlet 864 may have or be associated with an inverted cap 864 a thatmay be configured to prevent or obstruct solids from passingtherethrough into the effluent. The fluid (or effluent) F_(o1) may betransferred to additional flotation as applicable, or to filtration.

The amount of floatation may have a relationship to the amount ofcontamination—the greater the contamination, the more floatation thatmay be needed to remove floc and other contaminants to a desiredspecification, and vice versa.

In embodiments total retention or flotation time of fluid passingthrough the floatation skid 809 a may be in the range of about 30seconds to about 7 minutes. The vessel 853 may have a blanket gas, whichmay be nitrogen, fuel gas, or any other suitable blanket gas. The use ofthe blanket gas may help mitigate LEL's.

The filtration vessel 854 may receive an incoming fluid F_(i2) via aninlet 870. The incoming fluid F_(i2) may be that which has been treatedwith EC and/or DGF (e.g., F_(o1)). The filtration vessel 854 may be acompressible media vessel with an outer filtration vessel housing 874.

Compressible media 868 of the present disclosure may be advantageousover conventional filter cartridges and bulk media. Bulk media, forexample, is dependent on numerous factors such as size, media, what isbeing filtered, etc. Filter cartridges are not regenerable, and requiresignificant time and resources.

The compressible media 868 may be a unitary- or multi-piece structure ofany geometry or size suitable for compression and filtration. Thecompressible media 868 may be a porous structure. During compression theporosity (pore size) may be reduced, and thus the filtration abilityimproved. Fine particles may be captured, and solids loading may beimproved over that of bulk media.

The vessel 868 may include a compression assembly. The compressionassembly may be or include hydraulic-, pneumatic-, or motor-drivenpiston 869. There may be a first plate 872 a. There may be a secondplate 872 b. To promote or facilitate fluid flow through the vessel 854,and the filtration chamber 873, the plates 872 a, b may be perforated.The compressible media 868 may be positioned or otherwise disposedbetween the first plate 872 a and the second plate 872 b, and thuswithin the chamber 873.

Although not meant to be limited, FIG. 8B illustrates the first or topplate 872 a may be moveable in order to compress the media 868, whilethe second or bottom plate 872 b is stationary. However, embodimentsherein may have the bottom plate 872 movable and the top platestationary 872 b. In other embodiments both plates 872 a, b may bemovable.

Fluid may flow through the compressible media chamber 873 from eitherdirection as may be desired. Thus, fluid may flow either from the topdown, or from the bottom up. The vessel 854 may be configured to beswitchable therebetween. FIG. 8B illustrates the direction of flow maybe from the bottom to the top of the vessel 854.

The compressible media 868 may be polypropylene or polyethylene, orother porous compressible material (such as polyester) and/orhydrophobic. The vessel 854 may be operable with the compression media868 having a compression range of about 40% to about 60% from itsuncompressed state.

The floc or other contaminants present within the inlet fluid F_(i2) maybe readily captured with any suitable compressible media. In embodimentsfluid F_(o2) from the vessel 853 may be treated to filtration withinvessel 854. The filtration vessel 854 may be contemplated as a tertiaryfiltration system configured to receive flow from any part of a watertreatment system (e.g., 200), such as the EC skid (308) or the DGF skid809 a.

The compressible media 868 may be washed/backwashed (such as withpressurized water, air, or gas) as may be desired to clean the filterand remove the suspended solids trapped by the filter.

The vessel may include an outer housing 874, with a filtrationchamber/bed 873 positioned within the housing 874 between the first andsecond plates 872 a, b. The plates 872 a, b may be perforated and thusmay be configured with one or more holes/apertures (not viewable here)through which fluid may enter and exit the filtration chamber 873. Theperforations may be sized to facilitate ready fluid flow therethrough,but yet retaining the filtration media 868 therein.

As mentioned, first plate 872 a may be movable by way of the operablepiston 869 associated therewith. The plate(s) 872 may be moved asnecessary to control the degree of compression of the media 868. Inoperation, the media 868 may be compressed by the first plate 872 a.Influent F_(i2) may be distributed into the vessel 854 in a desiredlocation via inlet 870. The influent F_(i2) may be distributed evenlythrough the chamber 873 (and may flow upwardly the apertures in thesecond plate 872 b). The filtered fluid or effluent F_(i2) may exit thechamber 873 via apertures in the first plate 872 a, and may betransferred out of the vessel via outlet 871. Suspended solids may betrapped by the media 868.

It should be recognized that channeling of wastewater around the mediain the region of the wall of the housing 874, if it occurs, can bealleviated by providing a flow distribution device adjacent theapparatus wall to direct the flow of wastewater away from the wall andinto the filter bed. For example, a short baffle can be attached to thewall of the housing at regular intervals to extend into the filter bedby about two inches and at an angle of about 45 degrees upward to directthe flow of wastewater off the wall and into the filter bed.

For cleaning or maintenance, the inlet 870 and outlet 871 may bereversed, and the compressed media 868 returned to an uncompressedstate. Air (or other gas) or water (or other liquid) may be injectedinto the chamber 873 to facilitate decompression and cleaning trappedsolids from the media 868.

The vessel 854 may be configured with one or more spray jets (nozzles)867 a to aid in cleaning the media 868 and the chamber 873. The jets 867a may be oriented in a manner to cause a spinning action on the media868, thereby prompting an added cleaning benefit from centrifugal force.In addition to pressurized fluid, other agitation may be used, such as amechanical shaker (or comparable).

Referring now to FIGS. 9A, 9B, 9C, and 9D together, a horizontalcombination dissolved gas floatation-compressible media filtrationvessel, a partial-cut side view of a vessel like that of FIG. 9A, apartial-cut overhead view of a vessel like that of FIG. 9A, and aclose-up view of a dispersion member suitable for a vessel like that ofFIG. 9A, respectively, usable with system and process embodimentsdescribed herein, are shown.

FIGS. 9A-9D together illustrate a combination DGF/filtration vessel 953may be part of a post-EC treatment skid 909 with a horizontalorientation. Embodiments herein apply to the treatment skid 909 that maybe an inclusive assembly of a number of components, subcomponents, whichmay be further associated with operable systems, subsystems, assemblies,modules, skids, and so forth, including those described herein. Inembodiments there may be a single or a plurality of combination vessels953. The skid 909 may be operable in series, parallel, or as mayotherwise be desired. There may be a plurality of skids 909, such as an“A train” and a “B train”. The combination vessel 953 may haverespective piping, manifold, transfer pump, etc. to facilitate processfluid flow, particularly from outlet 977 to inlet 978, as well as fromzone 973 a to zone 973 b.

It is noted that while the combination vessel 953 may be referred to aspart of a ‘skid’ for simplicity, components of the skid need not be skidmounted. The vessel 953 may be part of an overall treatment system, suchas system 200. While they need not be exactly the same, vessels 953 mayinclude various features and components like that of other systems orunits described herein, and thus components thereof may be duplicate oranalogous.

Generally, there need not be any reject or bypass of outflow from ECunit operations described herein, so all (or substantially all) of theoutflow (including gas, bubbles, liquid, and floc) from a respective ECunit may be provided to the vessel 953. Thus, a fluid F_(i1) may be fedor otherwise received into the vessel 953 via an inlet 963. The skid 909may include an injection system 999. Dissolved gas or bubbles feedstream 989 may be introduced into the fluid inflow and/or into vessel953, such as via one or more injection points 967. Other forms ofgas/bubbles introduction may be used, such as induced gas flotation(IGF).

As shown here, the injection system 999 may include a dispersion formingmember 987 in fluid communication with various source streams anddischarge (or injection) points associated with the vessel 953. Themember 987 may be a high-shear mixer, dispersion pump, or any otherdevice suitable for forming a bubble-based mixture that may then beinjected into the combination unit 953.

The injection points 967 (with respective nozzles or ports) may belocated at various points on the vessel 953, such as at the bottom, theside, and combinations. For a synergistic advantage, gas generated(produced) in the EC unit (311) may be used for injection. However,other gas sources may be used, including gas from overheads 989 (via gasoutlet 989 a). In a similar manner, treated water from any unitdescribed herein may be used; however, other water or liquidous sourcesmay be used. An injection stream 922 a may be created by drawing fluidsand/or liquids varied sources, such as a pressurized tank.

The dissolved gas within the stream 922 a may be O2, O3, H2, air, or anysuitable gas for prompting floatation. Although shown here ashorizontal, the vessel 953 may have other orientations, such as vertical(see FIG. 10). The combination vessel 953 may be operated at atmosphericor pressurized conditions. The stream 922 a may include microbubbleshaving an average bulk diameter of about 10 microns to about 30 microns,but other bubble sizes are possible. The stream 922 a, upon release intothe vessel 953, may result in gas bubbles 922 released from dispersion.

The vessel 953 may be contemplated as having one or more compartments orzones 975 (e.g., 975 a-d). The first zone may be inlet zone 975 a, whichmay be where incoming influent fluid may be introduced via a dispersingmember 963 a. In this zone gas bubbles (or other suitable injectionstream) 922 a may be injected. The stream 922 may also be injected intothe inlet line 963 for immediate contact time and/or a separate gasinlet. The zone 975 a (and any other respective zone) may be delineatedfrom other zones via first flow diverter 976 a (or b-c, etc.). Anydiverter 976 may span the entire width and height of the zone but may befurther configured with a passage or opening 983.

It is within the scope of the disclosure that the vessel 953 may beconfigured with a first flotation zone, followed by a filtration zone,followed by a second flotation zone, followed by a second filtrationzone, and so forth.

Diverters 976 herein may be configured to inducing fluid to flow in aspecific path that promotes floating contaminates towards the oil/rejectbucket 918, as well as the liquid through openings 983. On any diverter976, and proximate to the respective opening 983, may be a box baffle962. Typically, the box baffle 962 will be on the outflow side of thediverter 976. The box baffle 962 (which may have a top opening 962 b anda bottom opening 962 a) may be configured for guiding fluid flow intothe next zone 965, as well as being proximate to the point whereinjection point 967 may be located (and thus contact with injectionstream 922 a). Although shown here as parallel to a vertical axis, thebox baffle 962 may have other orientations, such as any angle between 0and 180.

In embodiments, the box baffle 962 may be angled in a manner that urgesfluid flow to a side opposite of that of the oil bucket 918. Themomentum of the fluid hitting the opposite side may provide a caromeffect for any floc collecting on that side and provide additionalurging to move the floc toward the oil bucket 918.

Gasses and some solids or phase separated non-aqueous fluids may becollected at the top of any zone 975. The (micro)bubbles from gasinjection may facilitate push and/or float contaminates, oil, floc, andthe like to the surface for removal, which may be by skimming or othercomparable collection. This process may be repeated in subsequent zones975 b, c, with the water content improving in each subsequent zone.

During operation the vessel 953 may have a discernable liquid leveldifferentiated by water versus that of floc. The vessel 953 may have anoil bucket or weir-type structure 966 for capturing floc, oil, etc. Thefloc (or F_(L)) may exit the vessel 953 via an overhead outlet (notviewable here) and transferred therefrom. The fluid (or effluent) F_(o2)may be transferred to additional flotation as applicable, or tofiltration.

In the fourth or last zone 975 d, there may be an interim vessel outlet977 whereby fluid may transfer therefrom (such as via transfer region948) into an interim vessel inlet 978. The transfer region 948 mayinclude various piping, manifolds, pumps, etc. for transferring fluidfrom outlet 977 to inlet 978, and through the rest of the filtrationportion).

The filtration zone 973 may receive an incoming fluid, which may be thatwhich has been treated with EC and/or DGF. The filtration zone 973 mayhave a compressible media 968 having porous structure. The vessel 953may include a compression assembly. The compression assembly may be orinclude hydraulic-, pneumatic-, or motor-driven piston 969. As viewablein FIGS. 9B and 9C the vessel may have two separate filtrationcompartments (which may be operable as ‘coarse’ and ‘fines’ filtration.

Accordingly fluid may be introduced into the media filtration chamber973. Between compression plates 972 a, b, may be a compression media968. The compression media 968 may be suitable to further reduce theconcentration of oil and other undesirable contaminants.

Each respective compartment may have a first plate 972 a. There may be asecond plate 972 b. To promote or facilitate fluid flow through thevessel 953, and the filtration chamber 973, the plates 972 a, b may beperforated. The compressible media 968 may be positioned or otherwisedisposed between the first plate and the second plate, and thus withinthe chamber

The fully treated fluid F_(o2) may then pass out of the filtrationchamber 973, and out of the vessel 953 via outlet 971. The treated fluidF_(o2) may in some instances meet discharge specifications of less than15 ppm spec of hydrocarbons, contain no suspended solids or sheen, andpass toxicity.

Referring now to FIG. 10A, a partial cross-sectional side view of acombination electrocoagulation-flotation-filtration vessel, inaccordance with embodiments disclosed herein, is shown.

Embodiments herein apply to a treatment skid that may be an inclusiveassembly of a number of components, subcomponents, which may be furtherassociated with operable systems, subsystems, assemblies, modules,skids, and so forth, including those described herein. In embodimentsthere may be a single or a plurality of combination vessels 1008. Theskid, which may have one or more units 1011, may be operable in series,parallel, or as may otherwise be desired. There may be a plurality ofskids, such as an “A train” and a “B train”. The combination unit 1011may have respective piping, manifold, transfer pump, etc. to facilitateprocess fluid flow.

It is noted that while the combination unit 1011 may be referred to aspart of a ‘skid’ for simplicity, components of the skid need not be skidmounted. The unit 1011 may be part of an overall treatment system, suchas system 200. While it need not be exactly the same, unit 1011 mayinclude various features and components like that of other systems orunits described herein, and thus components thereof may be duplicate oranalogous.

The combination EC unit 1011 may be mounted to a frame-type structurevia one or more legs or support mounts. The combination EC unit 1011 maybe configured to interface or couple with a unit, operation, system,etc. whereby an incoming fluid from, for example, a source operation, apre-treatment vessel or skid, or a CIS (301, FIG. 3) may be received.Fluid F_(i) may be received into the EC unit 1011 via an inlet 1016, andupon treatment, may leave the EC unit via an outlet 1017 as a ‘treatedfluid’ F_(o).

The EC unit 1011 may be configured tantamount to an ANSI pressurevessel, which is to say the EC unit 1011 may be run under pressure. Inembodiments the operating pressure of the combination EC unit 1011 maybe about 50 psi to about 160 psi.

A first key aspect of the combination EC unit 1011 is the ability toprovide a reaction, flotation, and filtration effect within a singleunit, and thus significantly reducing size footprint.

A second key aspect of the combination EC skid 308 is the substantialreduction or outright elimination of passivation of powered electrodesby way of introduction of a sacrificial electrode or media (340). Thus,the EC unit 1011 may have a sacrificial or consumable media filled orotherwise disposed therein.

The EC unit 1011 may have one or more electrodes 1012 disposed thereinas described herein. The electrodes 1012 that may be alternatelyconnected to a respective positive and negative portion of a currentsource, such as the rectifier (not viewable here) (via two busbarconductors 1034—one connected to positive, one connected to negative).

The sacrificial media may be like that as described herein. Access toreplace sacrificial media may be provided via access portal 1079. Thecombination unit 1011 may have a first portion 1028 a, such as a top orlid, sealingly, but releasably, engageable with a bottom portion 1028 b.Because the EC unit 1011 may be pressurized, the unit housing (or outershell) may be metallic. The unit 1011 may have one or more innerhousings 1029 disposed therein. The inner housing 1029 may be made of anon-conductive material, such as polypropylene, fiberglass, carbonfiber, and so forth.

As shown here the unit 1011 may be generally cylindrical in shape, andthe inner housing 1029 may be generally rectangular prism (or box) inshape, however, embodiments herein are not meant to be limited and othershapes are possible. The coupling between

Fluid F_(i) may continuously flow freely through the unit 1011(including through the inner housing 1029 and related cells (volume ofspace between adjacent electrodes), as well as in contact with thesacrificial media (not shown here) and busbar(s) 1034). In embodimentsthe EC unit 1034 may be substantially liquid flooded and pressurized.

The busbar 1034 may be a conducting coupler type piece suitable fortransferring power (current) from a power supply or rectifier into theEC unit 1011, like that described herein.

Further consideration is required for the circumstance when the EC unit1011 may be operated under pressure, as the busbar 1034 must be coupledin a manner that does not result in the outer housing being electrified.Thus, a pressure gland assembly 1033 may be used (for each of thepositive and negative sides).

The pressure gland assembly 1033 may be like that as described herein,and thus having a gland body 1044 encapsulated or otherwise sealinglydisposed around at least a portion of a gland power bar 1047. A portion1050 of the gland 1033 may be sealingly compressed between faces ofrespective flanges 1025, 1032. Naturally there may be twoconfigurations, one for each of the positive and negative sides. Inembodiments, the spool piece may not be necessary, and a compressingflange face or other suitable structure may be suitable.

The gland power bar 1047 may be coupled to the busbar 1034 in a mannerso that it may be isolated from any contact with connection. The gland1033 may be configured to maintain pressure of the EC unit 1011 eventhough the power bar 1047 may pass or be encapsulated therein. On theother side, the gland power bar 1047 may be coupled to a rectifier powerbar, which then itself is electrically coupled within the rectifier (notviewable here).

The electrodes 1012 may be coupled with the busbars 1034 in analternating manner. That is, a first electrode (from left to right) 1012may be coupled with the busbar 1034 on the positive side at firstconnection (not viewable here, the first connection may include a jumpercoupled between the busbar 1034 and the electrode 1012). The second ornext electrode 1012 may be coupled with another busbar 1034 on thenegative side at second connection. This pattern may repeat itself asmay be applicable to the number of electrodes utilized, which may vary.In embodiments there may be between about 1 to about 14 electrodes. Inother embodiments there may be about 2 electrodes to about 6 electrodes.

As described herein the busbar(s) 1034 may be subjected to continuousliquid flow which may require consideration for mitigation or preventionof effects from electrolysis and deterioration.

In embodiments, a set of a cathode and a respective anode may have anassociated separation gap distance 315 in a range of about 3″ to about12″. In other embodiments, the gap may be in the range of about 5″ toabout 7″. A wide gap distance may advantageously promote use of the ECunit 311 in high capacity flow rate operations, yet at the same time notrequire excessive power normally required for conventional EC. As anillustrative example, a conventional EC unit may need to be operated at110 volts to accommodate gap distance, whereas the EC unit 1011 may beoperated at 10 volts for the same. In embodiments the voltage range maybe about 1 volt to about 20 volts.

During the operation of the unit 1011, coagulation of solids, oils, andother contaminants results in generation of the floc F_(L). In acontinuous operation, this may be ongoing with a limited residence timeof about 10 seconds to about 45 seconds. The operation of the unit 1011may also result in generation of gas bubbles. The floc and/or the gasbubbles may flow or otherwise be directed to a respective outlet 1065.

The EC unit 1011 may have inlet 1016 for receiving the fluid to betreated, and an outlet 1017 for the transfer of treated fluid therefrom.The flow of the fluid through the EC unit 1011 in combination with thesacrificial electrode may be continuous and may result in an effectivefluidized bed where the EC process occurs. Flow rates through the ECunit 1011 may be in the range of about 1 gpm to about 1000 gpm. In anembodiment the flow rate may be about 200 gpm to about 500 gpm.Embodiments herein readily facilitate treating upwards of 35,000 BPD ofcontaminated fluid, including for offshore, at reduced weight andreduced manhours compared to that of conventional treatment systems.

In contrast to EC unit 1011, the EC unit 1011 may have its inner housing1029 disposed (and in some instances supported by) a filtration zone1073 (NOTE: housing 1029 would be enclosed but is shown here with apartial cut internal view). One of skill would appreciate that in aliquid-filled vessel controlled by pressure, the unit 1011 may beoperable with adequate control to limit the amount of liquid goingoverhead to being substantially floc-based, with the rest of the liquidbeing pressure-driven into the filtration zone 1073.

Dissolved gas or other bubble-based stream 1022 a may be introduced tothe unit 1011 for flotation. The bubble based-stream 1022 a may beproduced by an injection system 1099.

Compressible media 1068 may be used comparable to that as disclosedherein. Although not viewable here, the combination unit 1011 mayinclude a compression assembly. The compression assembly may be orinclude hydraulic-, pneumatic-, or motor-driven piston. There may be afirst plate 1072 a. There may be a second plate 1072 b. To promote orfacilitate fluid flow through the filtration zone 1073, the plates 1072a, b may be perforated. The compressible media 1068 may be positioned orotherwise disposed between the first plate 1072 a and the second plate1072 b, and thus within the zone 1073. Thus, fluid may flow out of thehousing 1029, and from the top down through the zone 1073. Thecompressible media 1068 as described herein. The filtered fluid oreffluent F_(O) may exit the unit via outlet 1017. Suspended solids maybe trapped by the media 1068.

Embodiments herein provide for an electrocoagulation unit that mayinclude one or more of: an outer shell, an inner housing which may becoupled with the outer shell; a set of electrodes disposed within theinner housing, each electrode being separated from an adjacent electrodeby an electrode gap spacing. The outer shell may further include a fluidinlet; a fluid outlet; a first busbar opening; a and second busbaropening.

The unit may include a first pressure gland assembly sealingly coupledwith the first busbar opening. The pressure gland may include a firstgland power bar disposed within a first gland body. The unit may includea second pressure gland assembly sealingly coupled with the secondbusbar opening. The second pressure gland assembly may further include asecond gland power bar disposed within a second gland body.

The unit may include a first busbar coupled with the first gland powerbar. The first busbar may be coupled with every other electrode of theset of electrodes. The unit may include second busbar coupled with thesecond gland power bar. The second busbar may be coupled in analternating manner with every electrode of the set of electrodes notcoupled with the first busbar.

The unit may have a plurality (such as individual pieces) of sacrificialmedia disposed between each respective adjacent pair of electrodes.

An at least one electrode of the set of electrodes may have a(cumulative—front and back, etc.) surface area in a range of 1000 inchesto 2000 inches. An at least one electrode of the set of electrodes mayhave an electrode thickness in a thickness range of 0.1 inches to 2.5inches. The unit may have an electrode gap spacing between an at leasttwo of the set of electrodes comprises a gap distance of 4 inches to 8inches.

Any pieces of the sacrificial media may have perforations. In aspects,there may be set of perforations in a range of 3 perforations to 9perforations. Any of the pieces may have a media thickness of thesacrificial media is in a range of 0.001 inches to 0.005 inches.Naturally these dimensions refer to the media prior to use.

Any of the bars may have a main bar body made of conductive metal. Anyof the bars may have a surface coating. In embodiments, any of the barsmay have a first surface portion coated with a dielectric material, anda second surface portion coated with a conductive material.

Any of the electrodes of the set of electrodes may have a main electrodebody made of platinum. Any of the electrodes may have an outer electrodesurface coating. The surface coating may be a noble metal. Similarly,any jumpers of the unit may be made of a conducting material. Any of thejumpers may have a first jumper surface portion coated with thedielectric material, and a second jumper surface portion coated with theconductive material.

Embodiments herein pertain to an electrocoagulation unit that mayinclude one or more of: an outer shell (which may further have: a firstbusbar opening); an inner housing within the outer shell; a set ofelectrodes disposed within the inner housing, each electrode beingseparated from an adjacent electrode by an electrode gap spacing; afirst pressure gland assembly sealingly coupled with the first busbaropening, the first pressure gland assembly further comprising a firstgland power bar disposed within a first gland body; a first busbarcoupled with the first gland power bar, and further coupled with everyother electrode of the set of electrodes; and a plurality (such asindividual pieces) of sacrificial media disposed between each respectiveadjacent pair of electrodes.

In aspects, the inner housing may be centrally disposed within afiltration zone. The filtration zone may include: a first perforatedplate; a second perforated plate; and a compressible media disposedbetween the first perforated plate and the second perforated plate.

The unit may further include a fluid inlet; a fluid outlet; a secondbusbar opening; a second pressure gland assembly sealingly coupled withthe second busbar opening, the second pressure gland assembly furthercomprising a second gland power bar disposed within a second gland body;and a second busbar coupled with the second gland power bar, and furthercoupled in an alternating manner with every electrode of the set ofelectrodes not coupled with the first busbar.

Any of the sacrificial media may a media thickness in a range of 0.001inches to 0.01 inches.

Still other embodiments herein pertain to an electrocoagulation systemthat may include an electrocoagulation unit operably associated with apowers source and a flotation vessel.

The electrocoagulation unit may include an outer shell, the outer shellfurther may have: a first busbar opening; an inner housing within theouter shell. There may be a set of electrodes disposed within the innerhousing. Each of the electrodes may be separated from an adjacentelectrode by an electrode gap spacing. There may be first pressure glandassembly sealingly coupled with the first busbar opening. The firstpressure gland assembly may include a first gland power bar disposedwithin a first gland body. There may be a first busbar coupled with afirst end of the first gland power bar, and further coupled with everyother electrode of the set of electrodes. There may be a plurality ofsacrificial media disposed between each respective adjacent pair ofelectrodes.

The system may include the electrocoagulation unit pressurized to anoperating pressure in a range of about 50 psi to 160 psi. The unit maybe operated at a flow rate in a range of 200 gpm to 500 gpm. The flow offluid entering the electrocoagulation unit may have 1000 ppm to 5000 ppmtotal suspended solids (TSS).

The power source may be rectifier electrically coupled with a second endof the second gland power bar.

The power source may be operable to amps to the electrocoagulation unitin an amperage range of 300 amps to 500 amps. The power source may beoperable to provide volts to the electrocoagulation unit in a voltagerange of 1 volt to 20 volts.

The system may include the flotation unit operably associated with aninjection system. The injection system may be operated to form aninjection stream comprising bubbles having an average effective diameterin a range of 10 microns to 300 microns. The treated fluid may bereceived into the flotation vessel, and may mix with the injectionstream.

Any of the electrodes may have a main electrode body made of platinum,and any of the electrodes may have outer electrode surface coating madeof a metal material. The metal material may be or include a noble metal,such as ruthenium.

Any piece of the sacrificial media disposed into the electrocoagulationunit may include or be made of multivalent ion producing metal. Anypiece disposed therein may have a media thickness is in a range of 0.001inches to 0.005 inches.

Embodiments herein pertain to a method for removing contaminants from afluid that may include one or more steps of: disposing an amount of asacrificial media into an electrocoagulation unit; operating theelectrocoagulation unit at a pressure above atmospheric; receiving thefluid into the electrocoagulation unit; providing power to theelectrocoagulation unit from a power source to electrochemically treatthe fluid to form a treated fluid with a floc comprising coagulatedcontaminants; transferring the treated fluid to a flotation vessel;removing at least some of the floc via flotation to form a secondarytreated stream; removing other contaminants of the secondary treatedstream with a compressible media filtration vessel to form a treatedproduct.

The electrocoagulation unit of the method and respective components mayin accordance with embodiments herein. The flotation vessel of themethod and respective components may be in accordance with embodimentsherein.

Other embodiments herein pertain to method for removing contaminantsfrom a contaminated water stream that may include one or more steps of:disposing a plurality of individual pieces of sacrificial media into anelectrocoagulation unit; operating the electrocoagulation unit at apressure in a range of 50 psi to 160 psi; transferring the contaminatedwater stream into the electrocoagulation unit; providing power to theelectrocoagulation unit from a power source to electrochemically treatthe contaminated water stream to form a treated water stream with a flocportion comprising coagulated contaminants; and transferring the treatedwater stream out of the electrocoagulation unit.

The electrocoagulation unit of the method and respective components mayin accordance with embodiments herein. The flotation vessel of themethod and respective components may be in accordance with embodimentsherein.

The method may include the contaminated water entering theelectrocoagulation unit comprises water having 1000 ppm to 5000 ppmtotal suspended solids (TSS). The contaminated water may be provided tothe electrocoagulation unit at a rate of 200 gpm to 500 gpm.

The method may include the providing power step further compriseoperating the power source to provide amps to the electrocoagulationunit in an amperage range of 300 amps to 500 amps, and to provide voltsto the electrocoagulation unit in a voltage range of 1 volt to 20 volts.

In aspects the electrocoagulation unit may include a compressible mediafiltration zone.

Still other embodiments herein pertain to an electrocoagulation unitthat may include one or more of: an outer shell comprising a firstbusbar opening; an inner housing within the outer shell; a set of 4 to10 electrodes disposed within the inner housing, each electrode beingseparated from an adjacent electrode by an electrode gap spacing in arange of 5 inches to 7 inches; a first pressure gland assembly sealinglycoupled with the first busbar opening, the first pressure gland assemblyfurther comprising a first gland power bar disposed within a first glandbody; a first busbar coupled with the first gland power bar, and furthercoupled with every other electrode of the set of electrodes; and aplurality of sacrificial media disposed between each respective adjacentpair of electrodes.

In still yet other embodiments an electrocoagulation treatment systemmay include an electrocoagulation unit electrically coupled with a powersource.

The unit may include any of: an outer shell further comprising: aninlet, an outlet, and first busbar opening; an inner housing within theouter shell; a set of 4 to 10 electrodes disposed within the innerhousing, each electrode being separated from an adjacent electrode by anelectrode gap spacing in a gap range of 4 inches to 8 inches; a firstpressure gland assembly sealingly coupled with the first busbar opening,the first pressure gland assembly further comprising a first gland powerbar disposed within a first gland body; a first busbar coupled with afirst end of the first gland power bar, and further coupled with everyother electrode of the set of electrodes; and a plurality of individualpieces of sacrificial media disposed between each respective adjacentpair of electrodes. The power source may be a rectifier electricallycoupled with a second end of the first gland power bar.

Still other embodiments of the disclosure pertain to a water treatmentprocess that may include one or more steps of: associating the watertreatment process with an offshore operation; receiving a treated waterstream comprising floc into a flotation vessel; injecting an injectionstream into the flotation vessel to interact with the treated waterstream; removing floc from the treated water stream to form a secondarytreated water stream; filtering the secondary treated water stream in afiltration zone to form a treated water product; and discharging atleast some of the treated water product into the ocean.

The retention time of the treated water stream within the flotationvessel may be in a range of 30 seconds to 7 minutes. In aspects, theoffshore operation may be associated with a floating production storageand offloading (FPSO) vessel.

The filtration zone may be within a cylindrical filtration vessel. Thevessel may include a first perforated plate; a second perforated plate;and a compressible media disposed between the first perforated plate andthe second perforated plate. The secondary treated water stream may befed into the bottom of the filtration vessel and upward through thecompressible media opposite to an increasing porosity gradient of thecompressible media. The compressible media may include multiple piecesmade of either polypropylene or polyethylene.

The treated water stream may be received from a pressurizedelectrocoagulation unit operated at a pressure of 50 psi to 160 psi. Agas source may be generated within the electrocoagulation unit. Inaspects, the injection stream may be formed at least partially by usingthe gas source. The injection stream may include bubbles having anaverage effective diameter in a range of 10 microns to 300 microns

The flotation vessel may have a horizontal orientation. The flotationvessel may have a vertical orientation.

The process may include periodically uncompressing and cleaning thecompressible media, while at the same time continuing the filtering stepthrough a second filtration zone.

The treated product may include less than 15 ppm total suspended solids(TSS).

The electrocoagulation unit of the method and its components may be inaccordance with embodiments herein.

In aspects, the process may include feeding a flow of contaminated waterfrom the offshore operation to the electrocoagulation unit at a rate of200 gpm to 500 gpm. The flow of contaminated water may includecontaminants in a range of 1000 ppm to 5000 ppm total suspended solids(TSS).

Still other embodiments herein pertain to a fluid treatment process thatmay include one or more of: receiving a treated fluid stream comprisingfloc into a flotation vessel; injecting an injection stream into theflotation vessel to interact with the treated fluid stream; removingfloc from the treated water stream to form a secondary treated fluidstream; filtering the secondary treated fluid stream in a filtrationzone to form a treated fluid product; and discharging at least some ofthe treated fluid product from the process. Components, units, etc. ofthe method may be in accordance with embodiments herein.

And still yet other embodiments of the disclosure pertain to a methodfor removing contaminants from a fluid that may include the step of:disposing an amount of a sacrificial media into an electrocoagulationunit; operating the electrocoagulation unit at a pressure in a range of50 psi to 160 psi; receiving the fluid into the electrocoagulation unit;providing power to the electrocoagulation unit from a power source toelectrochemically treat the fluid to form a treated fluid with a floccomprising coagulated contaminants; transferring the treated fluid to acombination flotation-filtration vessel; and removing at least some ofthe floc and other contaminants via flotation and filtration within thecombination flotation-filtration vessel to form a treated product.Components, units, etc. of the method may be in accordance withembodiments herein.

Still further embodiments pertain to a water treatment process that mayinclude any of the steps of: associating the water treatment processwith an offshore operation; receiving a water stream comprisingcontaminants into a combination flotation-filtration vessel; injectingan injection stream into the flotation vessel to interact with the waterstream; removing floc from the treated water stream to form a secondarytreated water stream; filtering the secondary treated water stream in afiltration zone to form a treated water product; and discharging atleast some of the treated water product into the ocean. Components,units, etc. of the method may be in accordance with embodiments herein.

ADVANTAGES

Embodiments of the disclosure advantageously provide for improved fluidtreatment useable with a wide array of applications.

Embodiments herein may provide for EC fluid treatment having asignificantly reduced footprint over conventional treatment options.Other advantages include ability to significantly remove contaminantsthat may be toxic to sea life. The in-situ chemistry alleviates thereliance on other chemicals need for conventional chemical treatment.The EC fluid treatment of the disclosure may be suitable to completelykill bacteria, and work in low-conductivity systems to whichconventional EC is ineffective.

Treatment residence time within an EC unit disclosed herein may occurrapidly (under a minute) marking a radical advantage over conventionaltreatment options. Embodiments herein may be scalable and modular forhigh flow rates operations and/or constrained spatial requirements.

Advantageously one or more of electrolytic oxidation, emulsiondestabilization, electrocoagulation, flocculation, flotation, andfiltration may occur in a single combination unit. Combination unitstake up less space, and provide a smaller footprint. The use of a singleunit over, for example, multiple units, means less space, utility,instrumentation, and thus overall reduced capital expenditure. Easierand smaller also means less energy and less operational resources, andthus overall reduced operational

Embodiments herein may advantageously be used to treat a wide range ofcontaminants, organics, inorganics, metals, biologicals, with a singletechnology type.

Other advantages may include waste minimization, reduced storagelogistics, reduced liability exposure from handling waste, reducedenergy consumption, and the ability to use a waste to treat a waste.

Embodiments of the disclosure advantageously provide for new andinnovative systems, hardware, software, and related methods, fortreating a fluid. One or more embodiments herein may be retrofitted toexisting equipment. Embodiments of the disclosure advantageously providefor new and durable equipment units useable separately or together in awide range of onshore and offshore environments where fluid treatment isdesirous.

While embodiments of the disclosure have been shown and described,modifications thereof can be made by one skilled in the art withoutdeparting from the spirit and teachings of the disclosure. Theembodiments described herein are exemplary only, and are not intended tobe limiting. Many variations and modifications of the disclosurepresented herein are possible and are within the scope of thedisclosure. Where numerical ranges or limitations are expressly stated,such express ranges or limitations should be understood to includeiterative ranges or limitations of like magnitude falling within theexpressly stated ranges or limitations. The use of the term “optionally”with respect to any element of a claim is intended to mean that thesubject element is required, or alternatively, is not required. Bothalternatives are intended to be within the scope of any claim. Use ofbroader terms such as comprises, includes, having, etc. should beunderstood to provide support for narrower terms such as consisting of,consisting essentially of, comprised substantially of, and the like.

Accordingly, the scope of protection is not limited by the descriptionset out above but is only limited by the claims which follow, that scopeincluding all equivalents of the subject matter of the claims. Each andevery claim is incorporated into the specification as an embodiment ofthe present disclosure. Thus, the claims are a further description andare an addition to the preferred embodiments of the disclosure. Theinclusion or discussion of a reference is not an admission that it isprior art to the present disclosure, especially any reference that mayhave a publication date after the priority date of this application. Thedisclosures of all patents, patent applications, and publications citedherein are hereby incorporated by reference, to the extent they providebackground knowledge; or exemplary, procedural or other detailssupplementary to those set forth herein.

1. An electrocoagulation unit comprising: an outer shell, the outershell further comprising: a fluid inlet; a fluid outlet; a first busbaropening; a second busbar opening; an inner housing coupled with theouter shell; a set of electrodes disposed within the inner housing, eachelectrode being separated from an adjacent electrode by an electrodegap; a first pressure gland assembly sealingly coupled with the firstbusbar opening, the first pressure gland assembly further comprising afirst gland power bar disposed within a first gland body; a secondpressure gland assembly sealingly coupled with the second busbaropening, the second pressure gland assembly further comprising a secondgland power bar disposed within a second gland body; a first busbarcoupled with the first gland power bar, and further coupled with everyother electrode of the set of electrodes; a second busbar coupled withthe second gland power bar, and further coupled in an alternating mannerwith every electrode of the set of electrodes not coupled with the firstbusbar; and a plurality of sacrificial media disposed between eachrespective adjacent pair of electrodes.
 2. The electrocoagulation unitof claim 1, wherein an at least one of the set of electrodes comprises acumulative surface area in a range of 1000 inches to 2000 inches, and anelectrode thickness in a thickness range of 0.1 inches to 2.5 inches. 3.The electrocoagulation unit of claim 1, wherein the electrode gapbetween an at least two of the set of electrodes comprises a distance of4 inches to 8 inches.
 4. The electrocoagulation unit of claim 1, whereineach of the set of electrodes comprises a cumulative surface area in arange of 1000 inches to 2000 inches, and an electrode thickness in athickness range of 0.1 inches to 2.5 inches, and wherein the electrodegap between each adjacent electrode of the set of electrodes comprises adistance of 4 inches to 8 inches.
 5. The electrocoagulation unit ofclaim 1, wherein the sacrificial media comprises a set of perforationsin a range of 3 perforations to 9 perforations, wherein a mediathickness of the sacrificial media is in a range of 0.001 inches to0.005 inches.
 6. The electrocoagulation unit of claim 1, wherein each ofthe first busbar and the second busbar comprises a main busbar body madeof conductive metal, wherein at least one of the main busbar bodiescomprises a first surface portion coated with a dielectric material, anda second surface portion coated with a conductive material.
 7. Theelectrocoagulation unit of claim 6, wherein an at least one electrode ofthe set of electrodes comprises a main electrode body made of platinum,and an outer electrode surface coating selected from a group consistingof any noble metal, wherein the at least one electrode is coupled withits respective busbar via a jumper, and wherein the jumper comprises afirst jumper surface portion coated with the dielectric material, and asecond jumper surface portion coated with the conductive material. 8.The electrocoagulation unit of claim 1, wherein an at least oneelectrode of the set of electrodes comprises a main electrode body madeof platinum, and an outer electrode surface coating selected from agroup consisting of any noble metal.
 9. An electrocoagulation unitcomprising: an outer shell, the outer shell comprising: a first busbaropening; an inner housing within the outer shell; a set of electrodesdisposed within the inner housing, each electrode being separated froman adjacent electrode by an electrode gap; a first pressure glandassembly sealingly coupled with the first busbar opening, the firstpressure gland assembly further comprising a first gland power bardisposed within a first gland body; a first busbar coupled with thefirst gland power bar, and further coupled with every other electrode ofthe set of electrodes; and a plurality of sacrificial media disposedbetween each respective adjacent pair of electrodes.
 10. Theelectrocoagulation unit of claim 9, wherein an at least one of the setof electrodes comprises a cumulative surface area in a range of 1000inches to 2000 inches, and an electrode thickness in a thickness rangeof 0.1 inches to 2.5 inches.
 11. The electrocoagulation unit of claim10, the electrode gap between an at least two of the set of electrodescomprises a distance of 4 inches to 8 inches.
 12. The electrocoagulationunit of claim 11, wherein each of the set of electrodes comprises acumulative surface area in a range of 1000 inches to 2000 inches,wherein the sacrificial media comprises a set of perforations in a rangeof 3 perforations to 9 perforations, and wherein a media thickness ofthe sacrificial media is in a range of 0.001 inches to 0.005 inches. 13.The electrocoagulation unit of claim 11, wherein the first busbarcomprises a main busbar body made of a conductive metal, and furthercomprises a first surface portion coated with a dielectric material, anda second surface portion coated with a conductive material.
 14. Theelectrocoagulation unit of 13, wherein an at least one electrode of theset of electrodes comprises a main electrode body made of platinum, andan outer electrode surface coating selected from a group consisting ofany noble metal, wherein the at least one electrode is coupled with thefirst busbar via a jumper, and wherein the jumper comprises a firstjumper surface portion coated with the dielectric material, and a secondjumper surface portion coated with the conductive material. 15.(canceled)
 16. The electrocoagulation unit of claim 9, the unit furthercomprising: a fluid inlet; a fluid outlet; and a second busbar opening,wherein a media thickness of the sacrificial media is in a range of0.001 inches to 0.01 inches.
 17. An electrocoagulation unit comprising:an outer shell comprising a first busbar opening; an inner housingwithin the outer shell; a set of 4 to 10 electrodes disposed within theinner housing, each electrode being separated from an adjacent electrodeby an electrode gap in a range of 5 inches to 7 inches; a first pressuregland assembly sealingly coupled with the first busbar opening, thefirst pressure gland assembly further comprising a first gland power bardisposed within a first gland body; a first busbar coupled with thefirst gland power bar, and further coupled with every other electrode ofthe set of electrodes; and a plurality of sacrificial media disposedbetween each respective adjacent pair of electrodes, wherein each of theset of electrodes comprises a cumulative surface area in a range of 1000inches to 2000 inches, and wherein the first busbar comprises a mainbusbar body made of a conductive metal, and further comprises a firstsurface portion coated with a dielectric material, and a second surfaceportion coated with a conductive material.
 18. The electrocoagulationunit of 17, wherein an at least one electrode of the set of electrodescomprises a main electrode body made of platinum, and an outer electrodesurface coating selected from a group consisting of any noble metal,wherein the at least one electrode is coupled with the first busbar viaa jumper, and wherein the jumper comprises a first jumper surfaceportion coated with the dielectric material, and a second jumper surfaceportion coated with the conductive material.
 19. (canceled)
 20. Theelectrocoagulation unit of claim 17, the outer shell further comprising:a fluid inlet; a fluid outlet; and a second busbar opening, wherein asecond pressure gland assembly is sealingly coupled with the secondbusbar opening, the second pressure gland assembly further comprising asecond gland power bar disposed within a second gland body.